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Kanban Üretim Yönetim Sistemi

Üretimin tam zamanında gerçekleştirilebilmesi için tüm proseslere ne zaman ne kadar üretim yapacaklarını zamanında bildiren bir bilgi sisteminin kurulması gereklidir. Tam zamanında üretim sistemlerinde ve grup teknolojisinde bu işlevi gerçekleştiren Kanban sistemidir.
Kanban, Japoncada kart anlamına gelir.

Kanban üretim yönetim sistemi basit bir sistem mantığı olan, manuel ve düşük yatırım maliyetine sahip olan sistemdir. Yöntemin ilk uygulayıcısı Toyota firmasıdır.

TZÜ için kullanılan Kanban sistemi, esasında her hücredeki üretim miktarlarını uyumlu olarak kontrol eden bir bilgi-iletişim sistemidir. Kanban sistemi, TZÜ ortamında malzeme hareketlerinin kontrolü ve bununla beraber üretim etkinliklerini amaçlayan üretim kontrol (çizelgeleme) yaklaşımıdır.

kanban çalışma biçimi


Kanban üretim ve malzeme akışını kontrol etmek için kullanılan; üretim proseslerine neyi, ne zaman, ne kadar üreteceklerini ve nereye göndereceklerini söyleyen bir üretim yönetimi aracıdır. Kanban ile ürün ve bilgi akışı birlikte ele alınır, ayrı bir stok yönetimi gerekmez, fazla üretim engellenir ve israfların en aza indirilmesi sağlanır.

Kanban sisteminde, sonraki prosesler önceki proseslerden sadece tükettikleri miktarda ve zamanda parça talep eder ve çekerler. Kanban üretim sisteminde, üretim çizelgesi sadece son üretim prosesine (ya da darboğaz halindeki bir prosese) gönderilir. Hangi ürünün, ne zaman ve ne miktarda üretileceğinin sadece son proses tarafından bilinmesi bu prosesin önceki proseslerden sadece kendine gereken parçaları çekmesini sağlayacaktır ve böylece sonraki aşamanın parça çekimi olmadan önceki aşamada üretim yapılmayacak ve sonuçta her aşama kendisinden sonra gelen aşamanın ihtiyacını karşılamak üzere tam zamanında üretim yapacaktır. Bu da prosesler arasında oluşacak ara stokları ve stok düzeylerinde gözlenen dalgalanmaların minimize edilmesini sağlayacaktır.

Kanban plastik bir koruyucu içinde muhafaza edilen bir karttır. Kanbanlar fiziksel birimlerle birlikte hareket eden daima üretimin akışına ters yönde, son prosesten ilk prosese doğru hareket ederek üretim aşamalarını birbirine bağlar.

Kanban Çeşitleri ve İşleyiş Mekanizmaları
Kanban sisteminde kullanılan kartlar genellikle 10,6 x 20,32 dikdörtgen biçimi boyutlarda plastik karton veya metal olan ve üzerinde bilgiler taşıyan kartlardır. Genellikle kanban üzerinde yer alan bilgiler şunlardır:

  • Kullanıldığı yer (stok orijin noktası, tüketim noktası, taşıma yolu)
  • Parça numarası,
  • Parça adı,
  • Parçanın tanımı,
  • Kanban numarası (kanban kartının tanıtım numarası),
  • Parça sayısı / kanban (ana parçanın her üretim birimi için bu kanban tarafından siparişi açılan parça miktarı)
  • Kanbanın düzenli olarak konulduğu kutunun tanımlayıcı kod numarası veya ismi,
  • Kanbanın teslim edileceği iş istasyonunun yeri (kod numarası veya tanımı)

Kanban üretim kontrol sisteminde, tüketim ile tetiklenen parça / malzeme ikmali, temel olarak çekme, üretim ve tedarikçi kanbanları ile sağlanır.

Çekme/Taşıma Kanbanı

Çekme kanbanı, önceki hücrenin (müşteri hücre) sonraki hücreden (tedarikçi hücre) çekmesi gereken ürünün çeşidi ve kalitesini, bir sonraki istasyonun, bir önceki istasyondan çekmek istediği parça cinsi ve miktarını belirleyen ve parça / malzeme çekmek amacı ile kullanılan kanban çeşididir.

Ana montaj hatları ve iş istasyonları, girdi ve çıktı olmak üzere iki tip stok alanına sahiptirler. Girdi stok alanları, iş istasyonlarınca, kendi üretim süreçlerinde işlenmek üzere, standart kaplarda tedarik edilen ham madde, parça bileşeni ve/veya yarı mamullerin depolandığı alanlardır. Çıktı stok alanları ise, iş istasyonlarınca üretilen parçaların depolandığı alanlar olarak üretim ortamında bulunmaktadırlar. Eğer parça bizzat firmanın kendisi tarafından üretiliyorsa, girdi stok alanındaki her kapa iliştirilmiş bir çekme kanbanı bulunur. Bir kaptan tüketim başladığında, parçayı kullanan hücre çekme kanbanını kaptan ayırarak, tüketilen parçanın ikmali ile sorumlu hücreye iletir. Parçanın ikmali ile sorumlu hücre, çıktı stok alanında standart kaplarda üretimi tamamlanmış parçalara sahiptir. Kullanıcı, alınan kaba bir çekme kanbanı ekler ve kap ile çekme kanbanını söz konusu parçanın tüketimini gerçekleştiren montaj hattının ya da hücrenin girdi stok alanına transfer eder.

Çekme kanbanı hücreler arasında hareket eder. İki hücre arasında bilgi akışını sağlayarak, sonraki proses tarafından ihtiyaç duyulan parçaların, istenilen miktar ve doğru zamanda önceki prosesten teminini sağlar. Çekme kanbanı, bu yönüyle, tüketimle tetiklenen bir tedarik aracı olarak karşımıza çıkmaktadır.

kanban üretim sistemi

Üretim Kanbanı
İkmal ile sorumlu hücre, çıktı stok alanında üretimi tamamlanan, standart kaplar halinde depolanmış parça stokuna sahiptir. Bu kaplardan her birine iliştirilmiş üretim kanbanları vardır. Ana montaj hattı ya da iş istasyonu parça tedarikini gerçekleştirmek üzere çekme kanbanı getirdiğinde, kap üzerindeki üretim kanbanı kaptan ayrılarak, söz konusu parçanın ikmali ile sorumlu hücreye verilir. Bu şekilde, çıktı stok alanında tüketilen parçanın ikmalini sağlamak üzere üretim tetiklenir. Tedarikçi hücre, üretim kanbanında belirtilen miktarda üretim yaptıktan sonra, standart kapa üretim kanbanını ekleyerek ikisini çıktı stok alanına transfer eder.

Üretim kanbanı yalnızca tedarikçi hücre ile onun çıktı stok alanı arasında hareket eder. Üretim kanbanı çıktı stok alanı ile tedarikçi hücre arasındaki bilgi akışını sağlayarak parça ikmalini gerçekleştirir.

Tedarikçi Kanbanı
Tedarikçi kanbanı, tedarikçilerden satın alınan parçaların ikmalini gerçekleştirmek üzere kullanılan bir kanban çeşididir. Tedarikçi kanbanı, çekme kanbanına benzer şekilde, (satın alınan parçalar için) ana montaj hattı ya da iş istasyonunun girdi stok alanındaki kaplara iliştirilmiş halde bulunur. Kapta tüketim başladığında, kullanıcı tedarikçi kanbanını kaptan ayırarak, parçanın ikmali ile sorumlu tedarikçiye ulaştırır. Tedarikçi, tedarikçi kanbanındaki bilgiler doğrultusunda, parça ikmalini gerçekleştirir ve tedarikçi kanbanını kapa iliştirerek, kapın müşteri prosesin girdi stok alanına teslimini sağlar.

Tedarikçi kanbanı, müşteri firma ile tedarikçi arasında bilgi akışını sağlayarak, satın alınan parçaların tedarik sürecini gerçekleştirir. Tedarik süreci, tüketim ile tetiklenir ve bu süreç, tüketilen parçanın müşteri prosesin girdi stok alanına teslimi ile son bulur.