Cards Buffer
In some specific cases, the production line is producing KANBAN references and also products based on a shop-floor schedule. 2 solutions can be used:
Fixed Periods for non KANBAN references
A clear planning is necessary to define the periods during the week when the equipment produces non KANBAN references. This has to be done during the MPS.
At fix time you add at the end of the queue of your launcher the cards linked to the references not managed in KANBAN. The quantity or more exactly the equivalent time, has to be always the same and included in the KANBAN loop calculation in order to not create shortage on the KANBAN references. The production time dedicated to produce non KANBAN references is going to increase loops of all KANBAN references and as a consequence increase the inventory.
Cards Buffer
When this increase is not acceptable an other solution is to mix the 2 types of production modes by using a Cards Buffer.
A Cards Buffer collects all KANBAN cards consummed. It means that KANBAN cards are not going directly to their Batch Building Box but stored in this buffer. In order to keep the sequence of consumption, the Cards Buffer is a box with a cutted corner. KANBAN Cards have also the same corner cutted. Then when you put them in the Cards Buffer you have only one way to store them so the cards sequence in a Cards Buffer is exactly the consumption sequence.
At fixed period, the Scheduler takes cards from the Cards Buffer and feed himself the Batch Building Boxes. After each or x completed batch, he can inject a production of non KANBAN reference(s) in the Launcher.
In this case, it is possible to reduce the impact of the injection of non KANBAN references in the KANBAN reference loops size. If the time between 2 emptying of the Cards Buffer is lower than the average queue of the Launcher, the impact on loops is only the production time of the non KANBAN quantity injected.
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