- The Logistician takes the Kanban cards from the leveling or batching box corresponding to its time of passage.
- It places the Kanban cards at the top of the sequencer.
As for the operator, he takes the Kanban cards in accordance with the FIFO as his production progresses.
Production management tool
In addition to sequencing the production, it allows to visualize at a glance the advance/delay of the production, which allows the autonomy of the operators. Thus, we find on the Sequencer 3 zones of color and 4 behaviors:
- there is no Kanban: Production goes faster than demand. The lines and teams must be reconfigured to measure the Takt Time And no more, to avoid overproduction. You can use it to train or train staff or to do Lean activities (5S, Suggestion…).
- the Kanban is in the Green Zone: Production is aligned with customer demand and follows the level of Takt Time. The teams do not have to change behaviours and continue to produce at the indicated pace.
- the Kanban is in the Orange zone: Production is slower than the level of Takt Time and does not correspond to the expected delivery rate. You have to change the configuration of line and/or team to recover the situation.
- the Kanban is in the red zone: The delay is substantial and the risk is very important that we cannot deliver on time. It is necessary to make a plan of actions to return to a balanced situation (addition of hours of opening of the line, additional human resources…).
Defining color areas
When you set up the sequencer, you have to anticipate the different color zones. First rule: Use stickers to define these areas because they are taken to evolve over time.
Then to determine the size of each zone, use the following rule as the first approach:
- for the Green Zone: The number of Kanban located in the Green Zone is equal to 1 times the cycle of the Mizusumashi
- for the Orange zone: the number of Kanban located in the Green Zone is equal to 2 times the cycle of the Mizusumashi
- for the red zone: it corresponds to the rest of the size of the sequencer
R. Machado (2009) – Deployment of the stream drawn on a press line