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Fig. 3). The shelves were organized to have small stocks of
each reference. These shelves have a little inclination and a
few rollers, so that process of storage is more ergonomic
and the picking reliable. The material must be fed on the
back, whereas the picking of material must be realized on
the front. With this system, FIFO is guaranteed and the
material is consumed in the order that it is received.
The information of kanban cards are: (1) name and
reference of the component: there are components with
equal name but different references, so the reference is
fundamental to identify every component; (2) name of the
piece: EV6; (3) trip of the card: although the normal thing
is that kanban circuit have a place of beginning and other of
end, in this case, it does not happen this way, kanban only
circulates along the washing machine; (4) quantity and
special quantity: these quantities reflect the quantity of
original packing and another one for special orders which
the received quantity does not coincide with that of original
packing; (5) number of card and quantity of cards in
circulation: cards are numbered correlatively. Figure 4
illustrates it.
Another problem was the definition of the number of
cards because although there are known mathematical
formulae that define the exact number, the initial situation
was not very stable for the processes, so in certain
components, the requirements for extra stock was estab-
lished to cover the delays that these processes could
provoke. This definition is based on the experience of the
planners and for a moment of production at which the line
was not employed to 100% of its capacity. As this is a
flexible system, introducing or eliminating kanban cards is
possible to simply regulate the number of stock between the
processes [28].
Fig. 5 Kanban shelve with two kanban circuits
Fig. 6 Kanban circuit diagram
954 Int J Adv Manuf Technol (2009) 43:949–9586.2 Kanban circuit 1: shelves kanban in washing machine 1
To support the control of stock once received and to
facilitate the material requirements to the external store, a
special kanban has been designed, named Shelves Kanban.
The cards do not arrive to the provider because, in this first
phase, providers have not been included in the system, only
they have been informed about the need to receive lots as
the quantity of original packing to minimize the risks that
the manipulation supposes. The factory is connected with
this external store by electronic way and the request of
material is reported in the kanban.
The number of cards is limited, according to the quantity
by lot and of the necessary stock. Every lot that is received
is accompanied by a kanban card and is stored in the
shelves of washing machine #1 depositing the receptacles
on the back and later, when material is needed, taking the
material from the front following FIFO. The associated
kanban card is taken too and it is placed in a receptacle of
methacrylate (see Fig. 3) attached to the side of the shelves.
At the beginning of every work shift, the person in
charge of the washing machine will gather all the cards that
exist in the kanban receptacle and will order to the external
store the material that indicate the cards and in the quantity
that the same ones should indicate. It is important to use the
material in the quantities of the original packing to avoid
problems at the time of realizing orders.
As seen in Fig. 1, cups have a first machining before
they arrive at the washing machine. Although this process
is not realized near the washing machine, only the
personnel of this one are authorized to realize requests of