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Push Vs need pull
In the theory of production management, there are two completely different ways of guiding the production of plans to promote and demand-driven manner. It is well known that MRP is a classic example of a planned programme, MRP high-speed computing power and resources through computer centralized control, calculates the appropriate purchasing and production plans.
Taking into account a real enterprise has a certain amount of product categories, each species is complex, between a lot of common parts, replacement parts, a large range of customer needs, every part of the production cycle and inventory are different, so in this case only by MRP calculation to get an ideal production plan and purchasing plan.
However, changes in customer demand more and more diverse, faster and faster, in addition to the same product batch is getting smaller and smaller. In this case, if required after each needs to recalculate the MRP is absolutely unrealistic, not to mention some companies of MRP to run more than a few hours. So demand will become the preferred way to solve this problem, demand from the downstream process by passing the signal to advance additional resource-intensive demands of logistics controlling. Put simply guiding a process point or point of purchase drivers is the next demand (consumption), rather than through a complex calculation results. You can use the following chart:
Flow diagram can be seen from the above point of operation and under relevant, if we as a production system in the production pipeline, then the drive pipe and pull the pipe totally different.
Used promoted production of enterprise general middle inventory more, total production cycle (Tpc/t) more long, pipeline of "weight" not uniform, through on production by pipeline of source imposed "pressure" to production, can imagine pipeline in the of some link due to by "pressure" will appeared "jam" or other problem, on as Shang figure in the of repair,, and pipeline of end outflow products of speed not uniform, exists quality problem. Here we take a look at pulling system piping diagram:
Implemented pull production of enterprise will prior on production site do must of transformation, to do on "pipeline" of added can timely response, on "pipeline" within of the process balance beat, also to as reduced material of mobile away, process Zhijian of inventory points (if has necessary established inventory words) and operation points of production bulk of set as precise, and strictly implementation and so on.
Pull the pipe operation, uniform flow from the end while pulling on the individual's production was fed, the entire flow is on the back of "pull", "jam" little, short product life cycle, quality issues easier to control, and can be manufactured according to customer's actual needs, and can adapt to changes in customer demand.
So, to complete a pull system, needs a lot of support. Here we describe how to pull the signal transfer and production, is what we call the kanban (KanBan).
1. Process Control Board (IPKInProcessKanban)
Each station operator on what signals for production?
Very simple, in-station 2, for example:
If IPK2 is empty, for production, c, on IPK2;
If IPK2 c, but their operation over the production, c, after finishing his IPK2 null, c in IPK2, otherwise, the c in its operations
If the IPK2 and its operation are c, stop position 2 of the production until after IPK2 null, c on its operations to IPK2, again for production. (Stops production employees work arrangements can be used Flex Mobile or multi-equilibrium method, see in particular the ability to balance
By IPK the method, we can achieve one-piece flow, according to some of the characteristics of the product, not one piece flow, small batch flow can be achieved. In fact, if we have station capacity balance and coupling, logistics will work with stations, provided that these three operations, will naturally achieve the IPK.
I would point out that uses IPK the method the average online inventory number is equal to the position.