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Home / Products  / Software / Kanban system / HDF Kanban 
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    Description
     
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    Details
     
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    Benefits
     
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    Kanban methodology
     
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    Screenshots
     

Name
HDF Kanban

Description
HDF Kanban is an application, which was created to ensure full synchronization of manufacturing orders with the orders from customers . This application was developed on the basis of the most important principles of Kanban methodology. Kanban card (label with barcode) can be use both as a production order (Kanban - production card) and as a document describing the contents of container. In manufacturing Kanban cards are used to support production control and movement of materials , between warehouses and production, in the manufacturing process.

HDF Kanban implementation supports optimum management of stocks and helps to reduce stocks to a minimum. For production managers, HDF Kanban is an excellent tool to control the production and to respond to rapid changes in the market.

Construction of Application

Construction of Application

HDF Kanban application consists of three main modules:
  • BASE – main application
  • BRANCH – application designed to work in the branch/store
  • SRV – application which supports the exchange of data

Two additional modules of HDF Kanban application are:

  • main database (DB)
  • controller/configuration SRV service

Details

The idea of the HDF Kanban application, based on the example of a company which produces screws

Assumptions:
  • screws are supplied to each client in special containers
  • Kanban Card - the label with barcodes. Kanban card has a unique barcode, which allows the automatic registration of its movement and tracking of production processes


a)BASE creates orders and assigns them to products, then it creates “activation” In the base (BASE), it is also possible to generate reports: ”inventory at the customer” and “customer clearing ” The most important information in the reports include: product code, the number of containers, the number of units, the number of contract and consumption rates of individual products.
b)'Activation' are taken from the master database DB, and through the SRV, they are sent to an FTP server.
c)From an FTP Server ”activation” are imported by BRANCH.
d)In BRANCH labels are printed and empty containers are received to fill up. Products’ label can be used to mark the container. Each time after filling the container, a new label must be printed, for the product.



e)Data on the filling ratio of containers are sent to the FTP
f)SRV Service collects this data from an FTP server and placed in the main database (DB).

The description above is only an example to show the application in use.

HDF Kanban application is tailored every time to your individual needs and processes in your company. Our consultants will advise you, how to reduce or eliminate unnecessary costs in supply chain, using HDF Kanban. Before proceeding to the implementation of HDF Kanban applications, our consultants always carry out detailed analysis.

Analysis before implementation enables you to:

  • fully optimize the production processes
  • plan the optimum use of HDF Kanban system
  • to achieve 7 key objectives of the Kanban methodology no: shortages, delays, inventories, queues, idle, unnecessary technology and control operations, displacement)

Advantages

The primary objectives, which are taken into the consideration, when production control system, based on Kanban cards, is going to be implemented:

  • pressure to reduce the production cost
  • the need to decrease production time
  • the need for rapid response to demand signals from the market

Differences between the HDF Kanban system and traditional procurement system

traditional procurement system HDF Kanban system
stocks exist not exist
production Series long short
quality control of process only selected stages of the process the whole process
delivery time long, but within the limits of tolerance significantly reduced

Benefits from the HDF Kanban applications:

  • full synchronization of production with orders from clients
  • elimination of shopping costs (reduction of documents related to the production demands, requests, orders, etc.)
  • by shortening production cycles the capital turnover rate can be increased
  • the ability to react quickly to the changes in the market
  • reduce stock level in warehouse to the minimum
  • reduce the number of errors, by reducing the number of places where errors may occur
  • elimination of stores (assembly bin, technical store, finished goods warehouses are practically eliminated)
  • delivery on time
  • elimination of all elements from the manufacturing and service processes, which do not increase the value of products
For management, the implementation of HDF Kanban, means the ability to control the production process in real time, and rapid response to all the aberration and irregularities

HDF Kanban pozwoli na wyeliminowanie wszelkich strat powstających w procesie produkcyjnym:

Eliminate Get
eliminate excessive production of goods avoid downtime
eliminate the production of parts to stock free up frozen capital
eliminate unnecessary transport avoid unnecessary costs related to the movement of materials
eliminate downtime associated with waiting for the materials involve your workers in the operation, which will bring real profit to your company

Barcode on the Kanban card, connected to the automatic identification system, provides many opportunities for rapid identification and control.

  • full identification and traceability of the product
  • barcode (1D, 2D) allows you to insert in Kanban card required data about batch of products
  • the possibility of restoring the production process during each phase
  • fully accordance with FIFO
  • accurate records (real time) of all events, occurring in the production process allows to maintain the high quality of production, and eliminate the losses, delays and errors.
Kanban system is a perfect complement for the Warehouse Management System. Please get acquainted with the WMS offered by the HDF: DCI+ , which supports warehouse operations and management of the storage space in the company.

Electronic Kanban in DCI + system (module MySupplier)

The system was designed to organize the production, reduce the level of stocks, meet the deadlines of tasks and short delivery times. As a consequence, the level of materials in the warehouse is closely connected with the production and varies depending on needs.

Kanban methodology
Kanban is self regulated operational tool for control of production. Manufacturing process is organized in such a way, that each cell in the organization, produces exactly what is needed and when is needed. Deployment of application, which operates on the basis of this methodology, supports the optimal inventory control. Kanban card (e.g. label with barcode) may be considered as an instruction: "Whether or not to produce" and "How much to produce."

Production companies use Kanban cards to support the control of production and movement of materials in the manufacturing process between the warehouses and production. Kanban card may have a unique barcode, which allows the automatic registration of its movement and tracking production processes.

Kanban methodology assumptions:

Kanban = 7 x "no"
  • no deficiencies
  • no delays
  • no stocks
  • no queues – wherever and whatever
  • no idle
  • no unnecessary operations technology and control
  • no unnecessary movements/li>

Facts

Three years, after implementation Kanban methodology, Toyota has achieved:
  • 30% increase in production
  • 60% reduction of all stocks
  • 90% reduction of deficiencies
  • 15% reduction of production area
  • 15% reduction in operators, administrative and technical staff
In accordance with the Kanban methodology, the ideal state of production can be considered in situation, when manufacturing takes place at low level of stocks or even without stocks, according to the rule: right item, in the right place, in a right time, in a right amount (in accordance with the needs of the customer)

Screenshots
Assign permissions to users (BASE)
A user with administrator rights has the option to manage other users and their rights. This feature is available in options on the tab 'Users and Groups'. If the application is used by more that one person, it will be necessary to create different users and assign rights to each of them.
Control of deleted orders (BASE)
In options, you can have a access to deleted orders, (tab 'Order'), which allows you to restore deleted orders, when is needed.
Complete the list of contractors (BASE)
The first time you run the program, there is not any data, except the predefined user. To start the work with an application, a list of contractors should be supplemented and orders together with products must be entered.
A description of the contractor (BASE)
The contractor is described by a number of attributes, some of them (highlighted in red) are required and must be entered. The application differentiates two types of customers: the supplier and recipient. In the program, there is a option in which the contractor is both the supplier and the recipient or any of them.
The addition of the product to the order (BASE)
When product is added to the contract, it is very important to indicate which product code is placed on the container label. Depending on your choice, the information on selected code will be change.
The removal of the entire order or products included in the order (BASE)
Both the order and the products included in the order can be removed (you must have the appropriate permission)
Creating Activation (BASE)
When we have already entered the order and the products, we can create 'activation', which will enable the application, which works in a warehouse/branch (BRANCH) download data from an FTP server and import them to local database.
Reports generation (BASE)
After an upgrade in the application data base (BASE), you can generate statements/reports. There are two types of report: “inventory at the customer” and “final statement of customer” The scope of data covered by these reports, depends on the configuration of the filter.
Import of activation from an FTP server (BRANCH)
The relevant code must be entered into the window attributed to the activation code. If the code is correct the selected activation is imported from an FTP server.
The main application window (BRANCH)
In the main application window, you can preview the details of the order and products, print labels and change configuration.
Print labels (BRANCH).
Produces labels can be use to mark containers. Each time when the container is packed, a new label must be printed for the product.
Entering the code of empty container (BRANCH)
After you select the button 'Accept empty containers' the window to enter the codes of containers will appear. The codes can be entered manually or by using the barcode reader.
 

Benefits

Kanban = 7 x „no”

  • no deficiencies
  • no delays
  • no stocks
  • no queues – wherever and whatever
  • no idle
  • no unnecessary operations technology and control
  • no unnecessary movements
 
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