Production Control

Division of roles between the Kanban system and the scheduler

Using the Kanban method and the scheduler together

The Kanban system, which is the core of the Toyota Production System, is a system of operation at the manufacturing site to produce the orders received. Since only the "number of Kanban" (number of Kanban x number of units) required by the back-end process is produced by the own process, the flow rate of the Kanban can be fine-tuned to prevent overproduction in case of order cancellation.

(1)Stuck in the shipping area due to misalignment ⇒ (2)Returned to the processing area and held in the processing area ⇒ (3)When the processing point is reached, processing begins and the box is inserted. ⇒ (4)Back to 2.

The Kanban system is based on the premise that the production capacity is sufficient to meet the order, so it is difficult for parts manufacturers who deliver to automobile manufacturers to operate the system because the demand fluctuates rapidly as the subcontractor hierarchy goes down to "Tier 2" and "Tier 3" rather than "Tier 1".

The Kanban method is an operation method in which a problem is stopped each time it occurs and kaizen activities are carried out through the "Five Whys" (repeating the "Why" five times reveals the cause of a problem that was not initially visible), and then corrected repeatedly in the next month. The Kanban system is not a system to solve the overload of production resources in response to fluctuations in orders, so it is necessary to determine whether production is actually possible with a different system.

This is done by the production scheduler and the main bottleneck in the production process is the adjustment of the production process and to a certain extent the leveling of the production process to the facility unit and confirming that a feasible plan can be created the number of kanban sheets needed for the order quantity is calculated and the operation on site is handed over to the kanban.

System operation to be aware of MAX in-process inventory and raw material procurement

In Indonesia, the PSBB (Large-Scale Social Restriction) was enforced to prevent the spread of the new coronavirus, and both the purchase and production of automobiles have stagnated, resulting in a 79.6% decrease in Indonesian production in April 2020 compared to the same month last year (104,847 units to 21,434 units) and a 90.6% decrease in domestic sales (84,059 units to 7,871 units).

What we should be aware of in the economic stagnation phase is "prevention of overproduction" rather than "how much more we can produce", and one of the methods is to make a plan not to exceed the maximum inventory at the production planning stage and reliably digest the planned quantity on a daily basis.

It is difficult to systemize the work of making a production plan that does not exceed the maximum inventory, and even a slight delay in the plan can have a big impact on the subsequent process.

Because production delays can be caused not only by upstream factors such as additional orders and machine breakdowns, but also by downstream factors such as missing items due to delays in the arrival of raw materials, it is necessary to create a system to prevent shipping delays by allocating raw materials in the warehouse to high-priority orders that are confirmed or have already been delivered.


情報共有 1

The sharing of visible results leads to a common recognition of the problems, but if there are people who are troubled because the scarcity of information is diminished by the increasing sharing, the political power to increase the position by monopolizing useful information is at work.

インドネシアのスタバの店員にありがたい人生の教訓を教わった件 2

When you order your usual iced coffee at your regular Starbucks, a familiar clerk usually talks to you in a friendly and familiar way, like "You came at an unusual time today," or "Is your usual iced coffee okay today?

宗教によって異なる「死んだらどうなる」の考え方 3

Both Christianity and Islam are religions derived from Judaism and believe in the one and only God, Jesus Christ (God Himself) or Allah, respectively.

株価操作なんてインドネシア株では当たり前 4

Stock prices fluctuate with sell and buy orders, and if you get a lot of sell orders and a lot of buy orders, the other investors will follow suit with "me too" and the stock will go up.

心臓に毛が生えたインドネシア人のずうずうしい転職活動を応援してみた 5

Since many Indonesians can't maintain mental stability without revealing a secret story to someone else.

日系企業のインドネシアでの存在意義 6

If Japan's population continues to decline at the current rate, domestic demand will continue to shrink, and if this happens, it is inevitable that domestic companies that find it difficult to survive in the Japanese domestic market alone will look for ways to make a living in overseas markets.

チャンスはあるが勝てる分野が 7

After living in Indonesia, talking to people on my own, and gradually understanding the local situation, I realized that starting a business in Indonesia is surprisingly difficult. The reason for the difficulty is the high shipping costs and tariffs, the competition from local companies, and the high running costs of IMTA and DPKK.

インドネシアのシステムインテグレーション業界 8

The other day, I had the opportunity to exchange opinions with JETRO (Japan External Trade Organization) about IT investment by Indonesian SMEs, and they raised an important issue related to the existence value of system integrators, such as "How can we explain the cost benefits of system investment?

肉体と精神と心と魂 9

Speaking of "Body and Soul," it's the debut song of SPEED, a member of the LDP's House of Councillors, Eriko Imai, who was unofficially appointed as parliamentary secretary of the Cabinet Office following yesterday's cabinet reshuffle, and the name of a long-established Indonesian women's fashion brand.

ジャカルタのラーメン市場 10

I came to Indonesia for the first time in October 1997. I didn't understand Indonesian, my job was hard, the people around me were unreasonable, and there was a time when I wanted to go back to Japan for a while.

ブランド力、技術力、資金力の3要素 11

After the Jakarta riots of 1998, when the rupiah plummeted and domestic companies with foreign dollar-denominated debt were struggling to pay interest, I was looking for a new business in Indonesia that would allow me to earn foreign currency.

日本とインドネシアの間でのタイムマシン経営が通じなくなっている件 12

I think that Yoshinoya overcame the frame of Japanese food and became Indonesian soul food. I am happy to see the scene where Japanese food culture is accepted by Indonesian people.

不景気の歴史 13

Since I came to Indonesia, I have seen the economic recession several times, but because of the spread of the new coronavirus this time, the economy will definitely go into recession, and in a few years' time it may be called corona shock or corona recession.

日本のバブル経済崩壊後とインドネシアの通貨危機後 14

When I entered university in 1991, at the end of the bubble economy, land and stock prices were exploding, Mitsubishi Estate had bought the Rockefeller Center Building, a symbol of America, and the women of the one-length body-con (like the Bubbly Dance of Tomigaoka High School's dance club) were dancing at Juliana Tokyo in the waterfront bay area, waving their fans.

内需と外需の自国経済に及ぼす影響 15

The situation in Japan is that even if public works investment is made, the money stays in the savings of companies and individuals, and domestic consumption does not increase, while the situation in Indonesia is that even if domestic consumption increases, the ratio of imported consumer materials is high, and domestic assets are flowing out to foreign countries.

2019年の総選挙を前にインドネシア政治史のおさらい 16

As the campaign (Kampanye) for next year's presidential election (Pemilu Pilpres Pileg Indonesia 2019) is lifted, it has been decided that the order in which the ballot papers will be printed will be No. 1 for the incumbent President Jokowi and Vice President Mahuru candidate pair and No. 2 for President Prabowo and Vice President Sandiagauno candidate pair.

インドネシアの国土と風土が生み出す産地特有のコーヒー 17

Located in the coffee belt between the Tropic of Cancer and the Tropic of Cancer, Indonesia is a country suitable for coffee cultivation, and during the 300 years of Dutch colonial rule that followed the advance of the East India Company in 1602, Arabica coffee was brought to the country and cultivation began in the plateau region with a favorable climate.

-Production Control