FEATURE Supply chain, packaging & logisticsī
Kanban storage space and time-saving continuum
Kanban storage space and time-saving continuum
Standard container storage systems do not properly support Kanban because of their size and nature, warns Edward Hutchison, Managing Director of BITO Storage Systems
and just-in-time (JIT) logistics of parts needed in production. Typically, C-parts are cheap, yet still generate exactly the same processing costs as ordering a £10,000 A-part. The potential savings with C-parts lie less with the price and more with the ordering procedures and associated processing costs. With Kanban, the purchase order is automatically initiated as required for replenishment. There is a further cost saving with the Kanban principle due to it requiring less space for storage in valuable shop floor areas.
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any manufacturers require small components like nuts, bolts, fasteners and screws in the thousands,
relying on these so-called C-parts to keep the lines flowing just as much as the large components. Most likely they will be kept in bins on racking in their tens of thousands, readily available for picking. Many of these manufacturers will also be operating a Kanban system to provide efficient control of their production processes. Kanban is a method of self- regulating production using the pull or fetch principle in which data cards (called Kanban in Japanese) or more- advanced RFID tags are used to trigger individual production and logistics processes. The method fits best with a high proportion of identical parts that have a small number of variants. Operators working to Kanban decide how many of the small parts (screws, nuts, etc.) they need and when. In doing so, they are guided exclusively by their own requirement. This reduces long-term stockholding and at the same time guarantees a continuous supply to workstations and assembly points. The advantages of this method are decentralised control, lean warehousing
42 July/August 2024 | Automation
Best use of storage space However, it is commonly found that companies use standard container storage systems that do not properly support Kanban, because of their size or nature. Such systems will waste space. BITO, however, has developed special, torsionally rigid Kanban racking that takes up little space. CTB container racking allows 25% more C-part bins to be stored on shelves than other storage methods, thanks to an exceptionally thin base that doesn’t compromise on stability. The shelves of the CTB container rack are merely 20mm thick, which allows storing a significantly higher number of items.
The container racking is made from galvanised material and comes either with or without containers. A boltless design, which requires no additional screws or expensive tools, means it can be installed quickly and easily and there is plenty of flexibility for expanding that storage. The stable design allows a total load of 1,250kg to be stored. There are also CTB parts containers for storing C-parts. These have sliding front windows, allowing easy retrieval of parts without having to remove entire containers from shelves. This is
particularly useful when picking parts in production environments, where speed is key. The container is available with 300 or 400mm depths, 156mm width and 140mm height – dimensions perfectly matched to the shelf dimensions preferred in the Kanban process. These bins can be used in a ‘two-bin Kanban system’, which keeps reserve stock in one of the bins and provides a calculated number of parts to the workstation. The first crate is extracted from the shelf after the last part has been removed. The picker removes the card or RFID tag from the back of the box, triggering the ordering process. Then the second box is pulled in front, with theordered box with the supply parts then pushed in from behind, producing a FIFO flow of parts.
‘One-bin Kanban’ can also be used for parts that are neither very small nor only used in small quantities. For this purpose the Kanban bin must be divided into two with a transparent transverse divider. When the stock in the front compartment has been used, the operator removes the divider and allows the material to slide from the reserve stock to the picking position. The divider is then replaced.
Versatile bins C-parts bins are versatile: they are multi-functional and can carry loads to 15kg. They can be stacked, whilst allowing instant access to contents. Handles provide ergonomic access for retrieval of entire containers and labels can be applied for efficient organisation. They can be transported on a Euro pallet, making the best use of the space available, without any overhang. Having a complete Kanban system, which saves space and ensures operators can be supplied with those essential C-parts parts as required, continuously and efficiently, will be a major contributor to boosting manufacturing efficiency.
automationmagazine.co.uk
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