Production Control

Why is it said that the Kanban system does not require production planning?

Two types of Kanban system

To separate Pick-up Kanban from Instruction Kanban

The Kanban itself is clearly divided into two categories: movement instructions for the pick-up Kanban and production instructions for the Instruction Kanban.

The e-Kanban sent by email from the customer with shipping instructions is placed in a box in the shipping area. Replace it with a take-back kanban that is inserted, ship it together with the box to the customer (in this case, one box), and The original goods are checked with the shipping slip and e-Kanban. The replaced Pick-up Kanban remains at the Kanban post.

When a predetermined number of take-back Pick-up kanban left at the kanban post in the shipping area are accumulated (in this case, 2 kanban), they are returned to the assembly yard and replaced with Instruction Kanban that is inserted in the box, and the Instruction kanban is returned to the kanban post to pick up the 2 boxes in the shipping area.

When a predetermined number of Instruction Kanban in the assembly area are accumulated (4 Kanban in this case), they are returned to the assembly area to start assembly work.

For processes with short tact time, such as the molding process in the previous process, the forming process starts when the minimum stock is exhausted, using a signal kanban.

When an Pick-up kanban and an Instruction kanban are combined into an In-process kanban

Kanban is treated as an In-process kanban that rotates in the same process.

When the number of In-process Kanban left in the shipping area is accumulated, the In-process Kanban are returned to the Kanban post in the assembly area (in this case, 2 boards) and the 2 boxes are collected in the shipping area.

When the In-process kanban left on the kanban post in the assembly area, the Kanban is returned to the assembly area when the required number of Kanban have been accumulated (in this case, 4 Kanban), and assembly work begins.

The number of Kanban sheets is the total number of Kanban sheets (Kanban to be picked up and Kanban in progress) or the number of Kanban sheets in process.

  • Number of boxes required per day x (Kanban L/T + processing L/T + safety stock) = 1 x (2 + 4 + 0) = 6 boxes

Toyota needs to have a plan to put the product on a level playing field

The "pull-type" kanban system, which operates autonomously on the shop floor to take only the required quantity of items from the front-end process and produce only the quantity that is in short supply, is said to be in direct contrast to the MRP production plan created by the management organization using the "push-type" method.

In order to establish this input order schedule at the Toyota assembly plant, five or six deliveries are made every day. Theoretically, the subcontractor's plant is a subcontractor factory Even though it's not necessary for the company to create a production plan on the side, it still provides what you need, as much as you need, and when you need it Since the daily instructions require you to do the same variety in the same quantity, the daily instructions are leveled to produce the same variety in the same quantity. If the system is not standardized, it is difficult to prepare for production, such as arranging personnel and reconfiguring lines.

In every process, a system that allows us to manufacture the required amount of products at the required time is required. method, it is necessary to eliminate the variation in production volume and the variation in the type of goods, so that 100 units today, 100 units tomorrow, and It's a wasteful and costly way to keep the production system in place with a production that feels like one piece. Even if the Toyota assembly plant receives a large number of orders for the same vehicle model, it will still be able to meet the needs of its own line and those of its subcontractors. A schedule was set up to deliberately introduce vehicle models into the mixed flow line to avoid exceeding the production capacity of In other words, it is not necessary for the subcontractor plant to create a production plan because the Toyota assembly plant prepares a detailed production plan for leveling off.

In other words, it can be said that the reason why subcontractor plants do not need to create a production plan is that the Toyota assembly plants prepare a detailed production plan for leveling off.


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