Page 39 - MetalForming March 2014

PM-Luft also uses its barcodes to assist with paperwork and inventory tracking. Kanban cards (bar codes) are read and automatically entered into the OPS system, which functions as a levelized scheduling tool. Each slot represents a given allotment of pro- duction time (takt time).
The kanban system and Salvagnini’s automated production line enable PM- Luft to be exceptionally responsive to customer needs. Since installing the processing line, the firm has signifi- cantly improved product quality and now produces manufacturing output matched to the rate of demand. In addition, the kanban system provides PM-Luft with minute-by-minute flexi- bility on the production floor, so it can respond to any volume and variety of product with ease.
The Kanban Equation
Daily demand x (order frequency + lead time + safety time)
Number of kanban = Container quantity
Daily demand represents the num- ber of parts to be produced in a given day. I imagine that most sales forecasts reflect seasonal demands, so a recal- culation of the number of kanbans is vital to effectiveness as demand varies over time. A shop manager must try to predict the demand curve with the help of historical trends, recording the actu- al number of kanbans used for each product over the season.
For example, the X cabinet will have 10 kanban cards from January to March, 15 kanban cards from April to October and 12 kanban cards from November to December. This shows that demand peaks from April to Octo- ber. Perform this calculation at least once per month.
Order frequency represents the rate of material consumption over time, determined by dividing one day by the number of setups per day.
For example, one day divided by 0.25 setups/day equals an order fre- quency of four days. Normally you can
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