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Article
Publication date: 1 May 1997

A. Andijani

Investigates the trade‐off between the average throughput rate and the average systems time using kanban discipline. Considers a multistage serial production line system…

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1273

Abstract

Investigates the trade‐off between the average throughput rate and the average systems time using kanban discipline. Considers a multistage serial production line system with materials in the system controlled by kanban discipline. Presents simulation results to evaluate the production system performance in terms of the average throughput rate and the average system time for a fixed total number of kanbans over a given number of serial workstations. Constructs and compares efficient allocation sets for three and four workstations that are generated by kanban discipline for two processing time distributions, namely, uniform and exponential distributions. Based on the simulation results from three and four work‐stations, develops a general design rule to maximize the average throughput rate and to minimize the average system time. Analyses five and six workstations using the general design rule. Tests the validity of the general design rule by considering five and six workstations with a different number of kanbans. The results show that most of the efficient sets generated by the design rule are identical to those generated by enumerating all combinations of kanban allocations. However, using the general design rule reduces the simulation work tremendously.

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International Journal of Operations & Production Management, vol. 17 no. 5
Type: Research Article
ISSN: 0144-3577

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Article
Publication date: 8 April 2021

Jagan Mohan Reddy K., Neelakanteswara Rao A., Krishnanand Lanka and PRC Gopal

Pull production systems have received much attention in the supply chain management environment. The number of Kanbans is a key decision variable in the pull production…

Abstract

Purpose

Pull production systems have received much attention in the supply chain management environment. The number of Kanbans is a key decision variable in the pull production system as it affects the finished goods inventory (FGI) and backorders of the system. The purpose of this study is to compare the performance of the fixed and dynamic Kanban systems in terms of operational metrics (FGI and backorders) under the demand uncertainty.

Design/methodology/approach

In this paper, the system dynamics (SD) approach was used to model the performance of fixed and dynamic Kanban based production systems. SD approach has enabled the feedback mechanism and is an appropriate tool to incorporate the dynamic control during the simulation. Initially, a simple Kanban based production system was developed and then compared the performance of production systems with fixed and dynamic controlled Kanbans at the various demand scenarios.

Findings

From the present study, it is observed that the dynamic Kanban system has advantages over the fixed Kanban system and also observed that the variation in the backorders with respect to the demand uncertainty under the dynamic Kanban system is negligible.

Research limitations/implications

In a just-in-time production system, the number of Kanbans is a key decision variable. The number of Kanbans is mainly depended on the demand, cycle time, safety stock factor (SSF) and container size. However, this study considered only demand uncertainty to compare the fixed and dynamic Kanban systems. This paper further recommends researchers to consider other control variables which may influence the number of Kanbans such as cycle time, SSF and container size.

Originality/value

This study will be useful to decision-makers and production managers in the selection of the Kanban systems in uncertain demand applications.

Details

Journal of Modelling in Management, vol. ahead-of-print no. ahead-of-print
Type: Research Article
ISSN: 1746-5664

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Article
Publication date: 24 July 2020

Keita Matsuo and Leonard Barolli

Recently, Internet of Things (IoT) devices and sensors are rapidly increasing in the word. They are connecting to the internet and are generating vast packets in the…

Abstract

Purpose

Recently, Internet of Things (IoT) devices and sensors are rapidly increasing in the word. They are connecting to the internet and are generating vast packets in the network. Thus, the networks could be congested, and the performance will degrade. For this reason, it is important to decrease the number of transmitted packets. Agile is a technique to develop the software and manage the work efficiently. Kanban is a method to support Agile development. The purpose of this paper is to propose an IoT sensors management system considering Agile–Kanban and show its application for weather measurement and electric wheelchair management.

Design/methodology/approach

The authors present the design and implementation of two systems and show the measurement device, data communication failure and experimental results.

Findings

The proposed Agile–Kanban system can manage a large amount of IoT sensors and can decrease the IoT sensor’s consumption power thus increasing the IoT sensor lifetime.

Originality/value

By experimental results, the authors have shown that the proposed systems have good performance and can control the IoT devices efficiently.

Details

International Journal of Web Information Systems, vol. 16 no. 3
Type: Research Article
ISSN: 1744-0084

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Article
Publication date: 1 January 1985

Maling Ebrahimpour and Batoul Modarress Fathi

The implementation of the Japanese inventory control system, Kanban, in a production line, reduces Work‐in‐Process (WIP) inventory without affecting production or sales…

Abstract

The implementation of the Japanese inventory control system, Kanban, in a production line, reduces Work‐in‐Process (WIP) inventory without affecting production or sales, though there is a point at which the reverse becomes true. The hypothesis that Kanban policy would reduce total WIP inventory without affecting production/sales at all was tested under two environmental conditions, cyclical demand and constant growth demand, by means of a simulated model, and also showed that under cyclical demand, frequent starts and stops in the line due to use of all the Kanban cards will produce eventual growth in all inventories, if not rectified. It is hoped that further research will develop a sufficently comprehensive model to facilitate the implementation of such a materials handling system.

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International Journal of Operations & Production Management, vol. 5 no. 1
Type: Research Article
ISSN: 0144-3577

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Article
Publication date: 1 September 1995

Sea Ling and Bohdan Durnota

Modelling by means of specification languages is increasingly beingrecognized as an important phase in system development. It encouragesone to think about problems using…

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1537

Abstract

Modelling by means of specification languages is increasingly being recognized as an important phase in system development. It encourages one to think about problems using models organized around real‐world situations. The system to be developed should then be consistent, correct and unambiguous with respect to the models produced. The justin‐time kanban system is an example of a realworld problem with a multiple‐supplier and multiple‐client architecture. Uses two specification languages LOOPN and Object‐Z, proposed in the literature to model the kanbansystem. Focuses on describing the kanbansystem in the different notations, thus investigating how well they can express the just‐intime system. The kanban system consists of many replicated components, each having the same state space and exhibiting the same behaviour. To describe each and every component in the system would be repetitious and tedious. Discusses the ease of describing such a system.

Details

International Journal of Operations & Production Management, vol. 15 no. 9
Type: Research Article
ISSN: 0144-3577

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Article
Publication date: 17 February 2012

Roongrat Pisuchpen

In the real world many companies combine the operations of manufacturing, assembly and disassembly. Thus, the integration of just‐in‐time FMS, FAS, and flexible…

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1247

Abstract

Purpose

In the real world many companies combine the operations of manufacturing, assembly and disassembly. Thus, the integration of just‐in‐time FMS, FAS, and flexible disassembly system (DAS) models poses an interesting problem. The purpose of this paper is to provide major emphasis on a new simulation model for design and performance evaluation of a flexible assembly and disassembly system with dual Kanban under a stochastic system. This paper also primarily investigates the effect of varying the number of kanban cards, mean inter‐arrival time of demand and locations of the bottlenecks on the performance integration of JIT flexible manufacturing, assembly and disassembly systems.

Design/methodology/approach

Simulation is carried out in ARENA and data is analyzed using multivariate analysis of variance (MANOVA). This paper investigates the effect of varying number of kanban cards, mean inter‐arrival time of demand, and locations of the bottlenecks on the performance integration of JIT flexible manufacturing, assembly and disassembly systems. The performance measures that are simultaneously considered are the fill rate, work in process, and mean cycle time. This paper emphasizes that understanding the interactions between the variables and their effects on system performance is of utmost importance for managers in improving performance processes.

Findings

In manufacturing practice, there are many industrial units that represent the mixture of the referred three models. This paper presents a new simulation model for design and performance evaluation of a flexible assembly and disassembly system with dual kanban. The simulation results are statistically compared with MANOVA. MANOVA is used to perform the test with multiple objective functions, e.g. with the average production cycle time, percentage average fill rate, and work‐in‐process. The conclusion to be drawn is that minimized WIP can be obtained by higher percentage average fill rate, lower WIP, small average part cycles times, and increasing in kanban cards while simultaneously retaining full customer satisfaction.

Originality/value

The researcher presents the newly developed kanban system into the production system of JIT flexible manufacturing, assembly and disassembly system with simulation technique. Furthermore, by assigning time factors to the models, several performance measures can be easily computed. Then, the researcher tests the effect of the number of kanban card on integration of JIT flexible manufacturing, assembly and disassembly systems using a simulation approach, the simulation model is developed using the ARENA simulation package. The results are applied to a small case study. For a single product under the integration of JIT flexible manufacturing, assembly and disassembly systems, as the number of kanban cards increase, the fill rate along with work in process and the mean cycle time increases as well.

Details

Assembly Automation, vol. 32 no. 1
Type: Research Article
ISSN: 0144-5154

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Article
Publication date: 1 July 1990

N. Singh, Kwok Hung Shek and Dave Meloche

The application of the Kanban system in a practical environment isreported. The objective was to determine the optimal number of Kanbansfor each component part. The effect…

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1230

Abstract

The application of the Kanban system in a practical environment is reported. The objective was to determine the optimal number of Kanbans for each component part. The effect of the time interval between replenishment of parts on the amount of work‐in‐process inventory was also investigated. Prior to the implementation of the Kanban system, a computer simulation in GPSS was carried out. The results of the simulation run for different attributes are reported. An analysis of results is presented and the basic philosophy of just‐in‐time production, as well as the Kanban system, is discussed.

Details

International Journal of Operations & Production Management, vol. 10 no. 7
Type: Research Article
ISSN: 0144-3577

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Article
Publication date: 1 March 1997

Katsuhiko Takahashi, Nobuto Nakamura and Masanobu Izumi

Deals with the kanban system in just‐in‐time (JIT) production as a system of production planning and inventory control for multi‐stage production inventory systems…

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2714

Abstract

Deals with the kanban system in just‐in‐time (JIT) production as a system of production planning and inventory control for multi‐stage production inventory systems, Constructs a queueing network model of the kanban system with SLAM II. Aims to improve the kanban system by modifying the flow of information. Because the orders for all stages are released concurrently, the modified system is called the concurrent ordering system. By means of simulation experiments, investigates and compares the performances of the models.

Details

International Journal of Operations & Production Management, vol. 17 no. 3
Type: Research Article
ISSN: 0144-3577

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Article
Publication date: 1 July 2000

Ina S. Markham, Richard G. Mathieu and Barry A. Wray

Determining the number of circulating kanban cards is important in order effectively to operate a just‐in‐time with kanban production system. While a number of techniques…

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1396

Abstract

Determining the number of circulating kanban cards is important in order effectively to operate a just‐in‐time with kanban production system. While a number of techniques exist for setting the number of kanbans, artificial neural networks (ANNs) and classification and regression trees (CARTs) represent two practical approaches with special capabilities for operationalizing the kanban setting problem. This paper provides a comparison of ANNs with CART for setting the number of kanbans in a dynamically varying production environment. Our results show that both methods are comparable in terms of accuracy and response speed, but that CARTs have advantages in terms of explainability and development speed. The paper concludes with a discussion of the implications of using these techniques in an operational setting.

Details

Integrated Manufacturing Systems, vol. 11 no. 4
Type: Research Article
ISSN: 0957-6061

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Article
Publication date: 3 July 2017

Dênis Gustavo Leonardo, Bruno Sereno, Daniel Sant Anna da Silva, Mauro Sampaio, Alexandre Augusto Massote and Jairo Celso Simões

Shop floor control systems are generally major points of discussion in production planning and control literature. The purpose of this paper is to investigate how lean…

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1313

Abstract

Purpose

Shop floor control systems are generally major points of discussion in production planning and control literature. The purpose of this paper is to investigate how lean production control principles can be used in a make-to-order (MTO) job shop, where the volume is typically low and there is high variety. This paper examines the procedures involved in implementing a constant work-in-process (CONWIP)/Kanban hybrid system in the shop floor environment and also provides insights and guidelines on the implementation of a hybrid system in a high-variety/low-volume environment.

Design/methodology/approach

The authors review literature on Kanban, CONWIP, and CONWIP/Kanban hybrid systems to analyze how lean production control principles can be used in a MTO job shop. The second part focuses on the process of implementation. Using a case study of a manufacturer of electromechanical components for valve monitoring and controls, the paper describes how the operation is transformed by for more efficient shop floor control systems. Real experiments are used to compare pre- and post-improvement performance.

Findings

The study shows that the proposed hybrid Kanban-CONWIP system reduced the cycle time and achieved an increase of 38 percent in inventory turnover. The empirical results from this pilot study provide useful managerial insights for a benchmarking analysis of the actions to be taken into consideration by companies that have similar manufacturing systems.

Research limitations/implications

The statistic generalization of the results is impossible due to the use of a single case method of study.

Originality/value

This paper provides insights and guidelines on the implementation of a hybrid system in a high-variety/low-volume environment. The literature on real applications of hybrid CONWIP/Kanban by case study is limited.

Details

Journal of Manufacturing Technology Management, vol. 28 no. 6
Type: Research Article
ISSN: 1741-038X

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