KANBAN with 2 levels of Batch Building Boxes
Yasemin Esen
Yasemin Esen has successfuly implemented a KANBAN with 2 levels of Batch Building Boxes in Beitigheim (Germany). Her example inspired the one explained in this page.
Sometime the change over time is different when you change from a reference C to a reference A versus from a reference B to a reference A and this difference of time cannot be negligible. Generally it is the case when you have different families of change over and each of them involves a totally different process from the others.
We are taking the example of an extrusion line which produce rubber blades for wiper blades. We have 2 types of change overs:
- one to change the rubber material to be extruded. For this operation you need to purge the line, change all parameters, set-up the new material and start to produce till the line is able to produce the first good blade. The change over time is 40 minutes;
- one to change the length of the blade extruded. In this case you have to adjust the cutter. The change over time is 4 minutes.
The extrusion line produce 70 references with 30 differents lengths and 3 types of rubbers. The total allocated time for the change overs is 12% of the operating time.
How to set-up a KANBAN?
We are going to create 2 levels of Bach Building Box:
- one to manage the change over of the rubber;
- one to manage the change over of the blades length.
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