1st Edition

The Kanban Playbook A Step-by-Step Guideline for the Lean Practitioner

By Chris A. Ortiz Copyright 2016
    75 Pages 65 Color Illustrations
    by Productivity Press

    76 Pages
    by Productivity Press

    This book is intented for Lean practitioners and facilitators looking for a training tool and guideline that can be used in the work area while improvements are being made. It provides the most visible and detailed approach to Kanban implementation, so that they can see results in a short period.

    Cycle Counting and Baseline
    Introduction
    Creating a Kanban Sizing Report
    Cycle Counting, Part Identification, Vendors, and On-Hand Inventory
    Identification of New Inventory Quantities
    Calculating New On-Hand Costs
    Creating a Kanban Sizing Report

    5S and New Maximum Quantities

    Sorting
    Location Designations

    Kanban Cards

    Introduction
    Benefits of Kanban
    Kanban Defined
    Creating a Kanban Card System
    Break Down Items into Categories
    Establish Maximum Quantity: Usage Is Key
    Pros and Cons of Higher Maximum Quantities
    Pros and Cons of Lower Maximum Quantities
    Maximum Quantity Examples
    Establish the Minimum Quantity
    Establish Reorder Signal or Quantity
    Reorder Signal
    Kanban System for Supplies
    Supplies Are Delivered and Card Returned
    Maintenance Kanban Cards

    Two-Bin Systems and Material Handling

    Two-Bin Systems
    Material Handling
    Communication Lights
    Kanban Card or Bin Drop Point

    In-Process Kanban

    What Is a Pull System?
    External and Internal Customers
    Process Based (Push)
    In-Process Kanban (Pull)
    Pull System from Assembly to Paint
    Items Have Location on Rack
    Information and Signal
    How It Works
    Welding into Powder Coating
    IPK into Powder Coating Department
    Writable In-Process Kanban (IPK)
    Saw Operation

    Conclusion

    Definition of Terms

    Index

    Biography

    Chris Ortiz is the founder and president of Kaizen Assembly, a Lean manufacturing training and implementation firm in Bellingham, Washington. Kaizen Assembly’s clients include industry leaders in aerospace, composites, processing, automotive, rope-manufacturing, restoration equipment, food processing, and fish-processing industries.

    Chris has been featured on CNN Headline News on the show "Inside Business with Fred Thompson." He is the author of six books on Lean manufacturing. Chris is a frequent presenter and keynote speaker at conferences around North America. He has been interviewed on KGMI radio and the American Innovator and has written numerous articles on Lean manufacturing and business improvement for various regional and national publications.

    Chris is considered to be an expert in the field in Lean manufacturing implementation and has over 15 years of experience in his field of expertise.

    Watch Fred Thompson talk about Kaizen Assembly and Chris Ortiz on "Inside Business with Fred Thompson" at:
    https://www.youtube.com/watch?v=LMm3fVsbPtM