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1 7 8
1st 2nd
4
Ready 1 2 3 4 5 6 2 3 4 5
15
Machining 6 7 8 9 7 8
7
Fetting 9 10 11 1 10 11
17
15
8th 9th 15th
6 2 3 4 5 6 7 3 4 5 6 2 3 4
9 7 8 1 10 8
1 10 11 9 2 11
1 week over 2nd Week over
0
15th
5 6 2 3 4 5
1 7 8 1 7 8
9 10 11 9 10 11
2nd Week over 2nd Week over
Kanban Bin Calculation Sheet
E+H Monthly Reqt 175
Weekly Reqt 44
Daily Avg Production
Reqt (DDQ) 7
Stage
Transit
Lead Time
(TLT)
Production
Lead Time
(PLT)
Batch
Size
(Kanba
n Qty)
KQ
Delivery
minimum
lot size
(DMLS)
% of
Schedule
Adherence
(PSA)
Demand
During Lead
Time (DDL)
Toal No of
Kanban
Cards
(TNKC)
Total
Quantity of
Material
Max.
Stock
Min.
Stock
No of
Green
Cards:
NGC
Ready for Pack condition15 0 60 60 100% 109 5 300 300 175 3
Machining 20 15 60 60 100% 255 7 420 120 109 2
Fettling 0 20 60 60 100% 146 7 420 300 255 5
Shelling 10 0 60 60 100% 73 4 240 180 146 3
Wax Assembly 0 10 60 60 100% 73 3 180 120 73 21020 758 15
Wax
No of
Red
Cards:
NYC
2
5
2
1
111
Kanban Bin Calculation Sheet
A B C D E F G H I J K
E+H Monthly Reqt 182
Weekly Reqt 46
Daily Avg Production
Reqt (DDQ) 8
Stage
Transit
Lead Time
(TLT)
Production
Lead Time
(PLT)
Batch
Size
(Kanba
n Qty)
KQ
Delivery
minimum
lot size
(DMLS)
% of
Schedule
Adherence
(PSA)
Demand
During Lead
Time (DDL)
Number of
Cards
Necessary
for DDL
(Toal No of
Kanban
Cards)
(TNKC)
Total
Quantity
of
Material
No of
Green
Cards:
NGC
No of
Yellow
Cards:
NYC
No of
Red
Cards
:NRC
Wax Injuction/Raw Order 0 2 10 10 100% 15 3 30 1 1 1
Assembly/Forging 0 7 32 32 100% 53 3 106 1 1 1
Shelling/Machining 0 2 10 10 100% 15 3 30 1 1 1
Pouring 0 2 10 10 100% 15 3 30 1 1 1
Fettling 0 2 10 10 100% 15 3 30 1 1 1Ready for Pack
condition 0 2 10 10 100% 15 3 30 1 1 1
Wax
L
Prodn
capacity/
Day
300
300
300
300
300
300
Customer Monthly Reqt 1200 300
Weekly Reqt 300
*yellow cells are the input fields
Daily demand quantities*(DDQ) 50 Ml of units Pounds, grams, pieces, etc. (MI = metric increment)
Transport lead time days*(TLT) 5 Days Vendor lead time
Production lead time days*(PLT) 0 Days Internal lead time
Container/palett capacity*(Kanban Qty) KQ 32 Ml of units Pounds, grams, pieces, etc. (MI = metric increment)
% of Schedule Adherence (A) 100% Percentage internal attrition or scrap
Delivery minimum lot size* (DMLS) 32 ML hastes Defined according to vendor constrains or work center constraints
No of Location for Stock* NOL 0
Working Shifts/Day 2
Hours/Shift 8
Total Downtime 3
Shift Effn 80%
Safety stock (Percentage of demand during
lead time) Demand During Lead Time (DDL) 250 Ml of units A*(DDQ*(TLT+PLT)
Number of Cards Necessary for DDL (TNKC) 45 Number of cards
Safety Margin (No of Cards) 38 Number of cards
Total quantity of material 1450 Ml of units b5 (DDQ) = c11 1290
Days of demand coverage 29 Days b6 = (TLT)= B13
Total Required Inventory (TRI) =
DDQ*(TLT+PLT)*NOL 0 b7=(PLT) = C13
Average customer demand /Hr(Takt Time) 0
b8 KQ D13
Card Distribution b10 (DMLS) =E13
Above Reorder Point >> # of Green Cards NGC: 1 b18 (TNKC) H 13
Above Reorder Point >> # of Yellow Cards:NYC 7 Red Reorder points
Below Safety Margin >> # of Red Cards:NRC 37 Gre
Definition and Distribution of Kanban Cards
if IF(TNKC<=3,1,(IF(ROUNDUP(IF(TNKC<=3,1,((PLT+TLT)*DDQ)/KQ),0)+NGC>=TNKC,ROUNDUP(IF(TNKC<=3,1,((PLT+TLT)*DDQ)/KQ),0)-1,ROUNDUP(IF(TNKC<=3,1,((PLT+TLT)*DDQ)/KQ),0)))-NGC)
7.8125
37.5
45.3125
IF(TNKC<=3,1,(IF(ROUNDUP(IF(TNKC<=3,1,((PLT+TLT)*DDQ)/KQ),0)+NGC>=TNKC,ROUNDUP(IF(TNKC<=3,1,((PLT+TLT)*DDQ)/KQ),0)-1,ROUNDUP(IF(TNKC<=3,1,((PLT+TLT)*DDQ)/KQ),0)))-NGC)
IF(TNKC<=3,1,(IF(ROUNDUP(IF(TNKC<=3,1,((PLT+TLT)*DDQ)/KQ),0)+NGC>=TNKC,ROUNDUP(IF(TNKC<=3,1,((PLT+TLT)*DDQ)/KQ),0)-1,ROUNDUP(IF(TNKC<=3,1,((PLT+TLT)*DDQ)/KQ),0)))-NGC)
Customer Monthly Reqt 160 40
Weekly Reqt 40
*yellow cells are the input fields
Daily demand quantities*(DDQ) 7 Ml of units Pounds, grams, pieces, etc. (MI = metric increment)
Transport lead time days*(TLT) 0 Days Vendor lead time
Production lead time days*(PLT) 15 Days Internal lead time
Container/palett capacity*(Kanban Qty) KQ 32 Ml of units Pounds, grams, pieces, etc. (MI = metric increment)
% of Schedule Adherence (A) 100% Percentage internal attrition or scrap
Delivery minimum lot size* (DMLS) 32 ML hastes Defined according to vendor constrains or work center constraints
No of Location for Stock* NOL 0
Working Shifts/Day 2
Hours/Shift 8
Total Downtime 3
Shift Effn 80%
Safety stock (Percentage of demand during
lead time) Demand During Lead Time (DDL) 100 Ml of units A*(DDQ*(TLT+PLT)
Number of Cards Necessary for DDL + Earlier
stage safety stock Qty(TNKC) 11 Number of cards
Safety Margin (No of Cards) 9 Number of cards
Total quantity of material 360 Ml of units b5 (DDQ) = c11
Days of demand coverage 54 Days b6 = (TLT)= B13
Total Required Inventory (TRI) =
DDQ*(TLT+PLT)*NOL 0 b7=(PLT) = C13
Average customer demand /Hr(Takt Time) 2
b8 KQ D13
Card Distribution b10 (DMLS) =E13
Above Reorder Point >> # of Yellow Cards:NYC 3 Red Reorder points
Below Safety Margin >> # of Red Cards:NRC 8 Gre
Definition and Distribution of Kanban Cards
if IF(TNKC<=3,1,(IF(ROUNDUP(IF(TNKC<=3,1,((PLT+TLT)*DDQ)/KQ),0)+NGC>=TNKC,ROUNDUP(IF(TNKC<=3,1,((PLT+TLT)*DDQ)/KQ),0)-1,ROUNDUP(IF(TNKC<=3,1,((PLT+TLT)*DDQ)/KQ),0)))-NGC)
IF(TNKC<=3,1,(IF(ROUNDUP(IF(TNKC<=3,1,((PLT+TLT)*DDQ)/KQ),0)+NGC>=TNKC,ROUNDUP(IF(TNKC<=3,1,((PLT+TLT)*DDQ)/KQ),0)-1,ROUNDUP(IF(TNKC<=3,1,((PLT+TLT)*DDQ)/KQ),0)))-NGC)
IF(TNKC<=3,1,(IF(ROUNDUP(IF(TNKC<=3,1,((PLT+TLT)*DDQ)/KQ),0)+NGC>=TNKC,ROUNDUP(IF(TNKC<=3,1,((PLT+TLT)*DDQ)/KQ),0)-1,ROUNDUP(IF(TNKC<=3,1,((PLT+TLT)*DDQ)/KQ),0)))-NGC)
