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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.

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.

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.

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

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.

The aims of this paper is to investigate simulation‐based optimisation and stochastic dominance testing while employing kanban‐like production control strategies (PCS) operating dedicated and, where applicable, shared kanban card allocation policies in a multi‐product system with negligible set‐up times and with consideration for robustness to uncertainty.

Discrete event simulation and a genetic algorithm were utilised to optimise the control parameters for dedicated kanban control strategy (KCS), CONWIP and base stock control strategy (BSCS), extended kanban control strategy (EKCS) and generalised kanban control strategy (GKCS) as well as the shared versions of EKCS and GKCS. All‐pairwise comparisons and a ranking and selection technique were employed to compare the performances of the strategies and select the best strategy without consideration of robustness to uncertainty. A latin hypercube sampling experimental design and stochastic dominance testing were utilised to determine the preferred strategy when robustness to uncertainty is considered.

The findings of this work show that shared GKCS outperforms other strategies when robustness is not considered. However, when robustness of the strategies to uncertainty in the production environment is considered, the results of our research show that the dedicated EKCS is preferred. The effect of system bottleneck location on the inventory accumulation behaviour of different strategies is reported and this was also observed to have a relationship to the nature of a PCS's kanban information transmission.

The findings of this study are directly relevant to industry where increasing market pressures for product diversity require operating multi‐product production lines with negligible set‐up times. The optimization and robustness test approaches employed in this work can be extended to the analysis of more complicated system configurations and higher number of product types.

This work involves further investigation into the performance of multi‐product kanban‐like PCS by examining their robustness to common sources of uncertainties after they have been initially optimized for base scenarios. The results of the robustness tests also provide new insights into how dedicated kanban card allocation policies might offer higher flexibility and robustness over shared policies under conditions of uncertainty.

Considers a class of control systems known as generalized kanban control systems (GKCS) which can be used to implement a pull control mechanism in a manufacturing system. In a GKCS, the production system is decomposed into stages, where each stage consists of a production sub‐system. There are two design parameters per stage: one controls the work‐in‐process in the stage and the other determines the maximum number of finished products of this stage. Investigates the influence of these design parameters on the efficiency of generalized kanban control policies by deriving qualitative properties as well as using experimental results on the behaviour of GKCS.

Just‐in‐time (JIT) systems were originally designed for deterministic production environments such as constant processing times and smooth and stable demand. However, once implemented, JIT is fraught with numerous types of uncertainties, including variations in processing time and demand, planned interruptions such as preventive maintenance and unplanned interruptions such as equipment failure. These uncertainties lead to lowered production throughput, decreased machine utilization, increased order completion time and greater backlogs and overtime requirements. In this paper, we introduce a newly developed system, which we refer to as the flexible kanban system (FKS), to cope with uncertainties and planned/unplanned interruptions. We demonstrate the superiority of the new system by considering four case examples covering various uncertainties, conducting numerous studies and comparing the overall performances of the FKS with that of the traditional JIT system. In all the cases considered, the performance of the FKS was, indeed, superior to that of the traditional JIT system.

The aim of this paper is to develop an efficient analytical procedure to evaluate performance of the most general pull production systems particularly when multiple‐part‐types are involved. The authors consider a kanban controlled production system that can be modelled as a closed queuing network with different product classes. The production line is decomposed into stages which consist of one or several stations and an output buffer. Each stage is associated with a given number of kanbans. The main idea of this analytical algorithm is to analyze each subnetwork individually using a product form approximation technique. The iterative procedure is used to find the unknown parameters.

The authors design a multiclass queuing network that can be used to represent kanban controlled production systems. To solve this model, three procedures are used: decompose the original network into M subnetworks, convergence of unknown parameters in each subnetwork, and convergence of unknown parameters in the original network. The authors now describe these procedures separately.

The main contribution of this paper is the formulation of the problem of kanban controlled production systems with several part‐types. The methodology is based on approximate formula with decomposition and is applicable to more general manufacturing environments. The authors' method can be applied to both limited and unlimited demands. The analytical algorithm designed in this work has demonstrated excellent performance in analyzing kanban controlled production systems.

The methodology of this algorithm is based on approximate formula and is applicable to more general manufacturing environments.

Provides a comprehensive review of various modelling approaches related to Just‐in‐Time (JIT) manufacturing. JIT is essentially a philosophy for reducing lead time as well as excessive work‐in‐progress inventories. Based on this concept a number of techniques have been developed for the design, planning, scheduling and control of JIT manufacturing systems. Reports on a comparative study of these approaches for JIT manufacturing along with the conventional manufacturing approaches and alternative systems for JIT manufacture. Explores future research areas.

This paper aims to examine the introduction of Kanban production control, at a UK‐based electronic product‐manufacturing operation.

The paper covers key implementation issues, including cultural factors, the reasons behind the adoption of an electronic Kanban system, and explains in detail the working and benefits gained from the changes introduced.

Learning lessons from its previous lean implementation experiences, the company's adoption of Kanban was phased, and the final stage of gradually building up the parts under the control of the electronic Kanban was combined with broad involvement, widespread training and the addressing of cultural issues. This “pull” system has delivered the expected dramatic reductions in lead times and inventory but, having used Kanban to gain increased internal stability, the company is now planning to extend the system externally. Interestingly, to make this work, it will require the replacement of Kanban control in some internal areas of the plant with push control in the form of direct replenishment.

The paper clearly shows how effective the progressive introduction of aspects of lean can be in terms of delivering long‐term business benefits. It also confirms the importance of recognizing that even well organized businesses are liable to suffer pain when implementing lean. It is critically important not to blame the new system, but to find the real causes, and this requires understanding and training. Finally, in addition to explaining how the plant's new system operates, and observing some of the finer details of the electronic Kanban system, the paper looks at the interesting planned steps in the system's “evolution”.

The aim of the present work is to provide a case study where lean production (LP) techniques are implemented in a semi-automated assembly line with O-shaped (closed-loop) layout configuration. The action research has been conducted within an assembly line for automotive components. The work aims to provide insights on the impact of loop layout features with respect to lean principles’ application; operative solutions related to some logistic limit of loop layout; and how kanban technique can be adapted to an O-shaped layout.

The main research methodology is based on action research within an assembly line of oil pumps. The two research questions find answer through literature analysis and implementation of LP in the O-shaped layout. In the A3 step, we identify the main weak points of a loop layout also under the perspective of operators’ feeling. The analysis of the main constraints is conducted in this step, with respect to the most common layout used within LP adoption. Steps A4 and A5 answer to RQ2 by an on-field results’ analysis.

The use of an O-shaped layout may allow to improve ergonomic conditions for workers; to better organize parts feeding through slides and chutes because of the presence of operators outside the line. The new approach to determine the number of withdrawal kanban potentially extends the findings of Tardif et al. (2012): the minimum of the objective function is reached with a higher number of withdrawal kanbans.

The approach is applied within a stand-alone line, while in several industrial contexts, we may find several of these lines in the same shop floor. In this case, LP implementation would cope with the several kanban cards circulating, the over-saturation of the logistic operator in supplying all the lines with smaller quantities of materials.

The action research resulted in the introduction of a new concept of supermarket, conceived as a decoupling buffer that lies near the line and in the review feeding devices, with the adoption of bins and operators’ feeding chutes. Parts’ feeding systems is reorganized with a two levels of withdrawal kanban. The introduction of line supermarket and the change of supply policies from pallets to bins contributed to the strong reduction of average work-in-progress. Yet, the double-withdrawal kanban and the small quantities supplied may cause an increase of material handling times and meters covered by operators.

Better working condition of the line operators because of the presence of ergonomic chutes for parts’ feeding. In contrast, we observed a high saturation of logistic operator because of the small quantities of components supplied on the line, with an increased stress of this worker.

A decoupled withdrawal kanban (DWK) is developed. In DWK, the first withdrawal is issued to the supermarket that serves the line. The second withdrawal kanban is issued from the supermarket to the central warehouse. Within DWK, we propose a modified dimensioning formula through minimization of the objective function Z(k). Parts’ feeding is now organized with sliding chutes on operators’ workstations to collect components in accordance to kanban dimensioning.

The aim of this study is to develop a framework for the implementation of a Supplier Kanban System.

The research was conducted within a factory focusing on the warehousing and supplier-related operations using an action research methodology.

The study period spanning over six years was aimed to reduce the inventory and the manpower required to manage this inventory. This initiative led to a substantial average savings of more than 500,000 Malaysian ringgit annually.

The focus of the study is on a framework for implementing a Supplier Kanban System in a small or medium-sized company within the automotive industry.

This framework is designed to be self-sufficient such that the members of the organisation can use it without the help of external experts or consultants.

Reduction in inventory stored in the warehouse, the amount of redundant work carried out by the employees and other non-monetary improvements which are difficult to monetise resulted in a much better work environment and happier employees.

The change in the paradigm of the manufacturing value chain affects the Tier 1 and 2 suppliers in Malaysia. The lines and value chains posing challenges to the suppliers have brought the idea of the Supplier Kanban System. The Supplier Kanban System adopted the action research cycles and continuous learning cycles, and this process was documented and developed as the Framework for the Implementation of a Supplier Kanban System.

This paper presents a new generic Petri net (PN) model for design and performance evaluation of a flexible assembly system (FAS) and disassembly system (DAS) with dual kanban. The architectural design of the model is derived from a generic bill of materials (BOMs) in the FAS, a reverse BOM in the DAS and the process plan in the case of flexible manufacturing system (FMS). Integration of FMS, FAS and DAS by developing a new generic PN model with the pull system is introduced. Analysis and performance evaluation of the new model based on invariant analysis and linear programming are also introduced. The method will be illustrated by a small case study.