Kanban Card—Key Exercises

Basic Data Setup

Setup a Kanban Circuit with a Visual Signal Type and a Calculated Demand

Purpose: The purpose of this exercise is to set up a Kanban Circuit to create Kanban cards that can be used in a visual Kanban production system.

Windows:
Kanban Circuit

  1. Open the Kanban Circuits window and query for the part number RW100.
  2. Make sure the circuit is in the Active status.  If it is not, then make it so.
  3. Click the Detail tab, and change the signal type to Visual (not electronic).
  4. Click the Calculation Inputs tab and enter the following:
    5.  Field Value
    Demand Quantity 32
    Demand Source Kanban Circuit
    Leadtime 1
    Calculation Type Number of Kanbans
    Formula Type Basic
  5. Save your changes (F12).
  6. Right-click and then click Calculate Kanbans.  

General exercise for Kanban Circuit 
General exercise for Kanban Planning Tools

Main Lesson

Purpose: The purpose of this lesson is to demonstrate how Kanban cards are managed in a visual Kanban production system.

Windows:
Kanban Circuit
Kanban Cards Report

Generate Kanban Cards

  1. Open the Kanban Circuits window and query for the part number RW100.
  2. Click the Recalculation tab to view the calculation results.  The recalculation information should be as follows:
    3.  Field Value
    Qty per Kanban 4
    No of Kanbans 8
  3. Right-click and then click Accept the Calculations to generate cards.
  4. Click the Calculation Inputs tab and change the calculation type to Kanban Qty, and increase the demand quantity to 40.
  5. Right-click and then click Calculate Kanbans.
  6. Click the Recalculation tab to view the calculation results.  The recalculation information should be as follows:
    7.  Field Value
    Qty per Kanban 5
    No of Kanbans 8
  7. Right-click and then click Accept the Calculations to generate cards.
  8. Click the Cards tab to view the Kanban card generation results.  The cards should all be Obsolete.
  9. Click the Calculation Inputs tab and change the calculation type to the Number of Kanbans, and decrease the demand quantity to 32.
  10. Right-click and then click Calculate Kanbans.  Right click and then click Accept the Calculations to generate cards.
  11. Click the Cards tab to view the Kanban card generation results.  There should be eight new cards.
  12. Select six cards, right-click and then click Deploy Card(s).  Notice the change of status.
  13. Click the Calculation Inputs tab and change the Demand Quantity to 16.  Save the changes (F12).
  14. Right-click and then click Calculate Kanbans.
  15. Click the Recalculation tab to view the calculation results.  The recalculation information should be as follows:
    16.  Field Value
    Qty per Kanban 4
    No of Kanbans 4
  16. Right click and then click Accept the Calculations to update the cards.
  17. Click the Cards tab and view the changes.
  18. Create a non-replenishable card by selecting New (F5) in the table, and changing the Kanban replenishable option to Not Replenishable in the new record.  Save the changes (F12).

Printing Kanban Cards

  1. Open the Kanban Circuits window and query for the part umber RW100.
  2. Click the Cards tab to view the Kanban cards for the circuit.
  3. Select the the new cards in the table.  Right-click and then click Print Selected Kanban card(s)
  4. Right- click and then click Deploy cards, and click OK in the Print Kanban Card(s) window.
  5. Click Print in the print window to create a printout of the card, or click Cancel.
  6. Notice that the information in the Kanban Print Flag, the Last Print Date, and the Number Times Printed fields is updated for the card.
  7. Open the Kanban Cards Report window and enter the following values:
    8.  Field Value
    Part No RW100
    Replenish Type Production Line
    Replenish Source RWL
  8. Clear the Print only cards marked Not Printed check box.
  9. Click OK.
  10. Review the report results in the preview window. 

Verifying Valid Cards

  1. Open the Kanban Audit Report window and enter the values for your Kanban circuit.
  2. Click OK.
  3. Review the report results in the preview window.
  4. Open the Kanban Circuits window and query for the part number RW100.
  5. Click the Cards tab.
  6. Select the obsolete cards in the table. Right-click and then click Remove Card(s).
  7. The cards are now considered removed from circulation.