Kanban As A Tool of Lean Manufacturing Six Sigma

The goal of lean manufacturing Six Sigma is to increase performance and efficiency, while reducing waste. Implementation requires the use of tools that reduce or eliminate wasted time and materials associated with any given process. In practical terms, this involves controlling, or capping, the number of items within a manufacturing process. Implementation of the Pull or Kanban system can be an effective choice to provide this control, as well as manage lead-time.

What is Kanban

Kanban is a term derived from two Japanese words; kan meaning "sign" or "card" and ban meaning "signal". This system is used to mark a cycle within the manufacturing process. At one end of this cycle are raw materials, at the other, a completed product.

In a manufacturing environment, Kanban is used to signal the need for some item. For example, an assembly station may include two bins, the first is to contain materials and the second is for a completed unit. Both bins are kanbans. When emptied, the first bin signals the need for additional raw materials. An empty second bin, similarly, signals the need to produce a completed product to meet customer demand.

Both kanbans are intentionally sized to control the amount of materials available at any one time. Since the incoming bin may contain only a specific amount of raw materials, no excess materials are allowed to accumulate, taking up valuable manufacturing floor space. In addition, the sizing of the second bin helps to ensure that production meets the level of the customer demand. By controlling this factor, excess inventory does not accumulate either. The manufacturing process is regulated to meet demands without a build-up of unnecessary stocks that impede efficiency.

Overall, a Kanban system optimizes the availability of materials, providing just what is needed at any one time. By regulating the flow through the manufacturing environment, inventories are synchronized with need. This contains wasted time and space, keeping costs to a minimum.

Benefits of Kanban

  • The process is simple, understandable and easy to implement.
  • Detailed information is readily available.
  • Information transfer costs are minimized.
  • The process is responsive to environmental and economic changes.
  • Amount of processes running over-capacity is limited.
  • Overproduction is avoided.
  • Waste is reduced.
  • Control over inventory, costs and productivity is maintained
  • Responsibility is delegated throughout the process.

Kanban and Lean Manufacturing Six Sigma

By definition, a lean manufacturing system meets demands without carrying excessive inventory. By effectively managing resources, a Kanban system can help ensure production is efficient and manufacturing performance consistently meets consumer demands; a core premise of lean manufacturing Six Sigma.