Kanban Replenishment

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Kanban is a means of supporting pull–based replenishment in manufacturing systems. A Kanban system is a self–regulating pull system that leads to shorter lead times and reduced inventory. Kanban systems are typically applied to items that have relatively constant demand and medium–to–high production volume.

Kanbans represent replenishment signals that are usually manual and highly visible, such as a color–coded card that moves with the material, a light that goes on when replenishment is required, or an empty bin that is moved to the supply location to trigger replenishment.

The system includes an API that can be called by external systems, such as bar code readers, to trigger replenishment signals.  Kanbans can be replenished from an external supplier or an internal organization.

The four types of kanbans available in the system trigger transactions that pull material from different replenishment sources.
Inter Org Creates internal requisitions
Intra Org Triggers material movement from a subinventory in the same organization
Production Creates or releases a production job (discrete job, repetitive schedule, or flow schedule)
Supplier Creates a purchase requisition

Kanbans are generally replenishable and cycle through the system from full to empty, remaining active until they are
withdrawn. One–time signals, called non–replenishable kanbans, are used primarily to manage sudden spikes in demand.

Coined from the Japanese word kan which means “card”, and ban which means “signal”, kanban is simply described as a system for “pull” production control. When we talk of “pull”, it is more of a control measure to release materials into production “only when they are needed.”

On the other hand, the “push” system is a transposition of the “pull’ production system. “Push” is thereby releasing materials into production as customers’ orders are processed and the materials become available. Material Requirement Planning or Manufacturing Resource Planning (MRP) modules are typical “push” systems.

Some may say that Kanban is more of a visual scheduling system. The emphasis here is that Kanban is not a system where everything is put on schedule, it must be made clear that Kanban is a production control system intended to enable the process owner to easily view production requirements and ensure that parts or supplies are ordered/procured only if necessary.

Kanban is generally used in two instructional forms:
1. A simple production instruction (shikake) indicating what, where and when it is needed, and where materials are coming from or going to; and

2. The other form is for parts withdrawal (hikitori) or an illustrated piece to visually communicate materials that have been consumed and their quantities that need to be replaced by upstream processes.

The purpose of Kanban is, therefore, to automate the inventory controls without the need of analysis or planning. 

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