Optimal Kanban Number: An Integrated Lean and Simulation Modelling Approach

Kanban is credited as a major means to controlling the inventory within a manufacturing system. Determining the optimum number of Kanban is of great interest for manufacturing industries. To fulfill this aim, an integrated modelling approach using discrete-event simulation technique and Kanban Lean tool is developed for a pull system ensuring an optimum Kanban number. This research has developed a base-case simulation model which was statistically validated using ANOVA. Initial Kanban number obtained from the mathematical model of Toyota motor company is used to obtain initial results. A Kanban integrated simulation model is developed that employed the idea of pull system that required the arrival of a customer for a product and Kanban pair to proceed through the production steps. The Kanban-Simulation integrated model is further used to test the effect of different Kanban numbers to obtain the best value of Kanban which is selected as 275. This approach has been applied on a case company involved in the manufacturing of agricultural and construction metal hand tools. The optimum Kanban number is selected by simulating the model about three performance indicators: customer waiting time, weekly throughput, and Work-in-progress. The analysis of the results obtained from the proposed integrated Kanban-simulation model showed a 76.7% reduction in the inventory level. The integrated Kanban-simulation model has also given a minimum customer waiting time of 0.84 Hrs. and a maximum throughput value of 737 Pcs of shovels. The integrated Kanban-simulation model is useful for manufacturing industries working to avoid overproduction waste and greatly reduce inventory costs

A Performance Evaluation of a Lean Reparable Pipeline in Various Demand Environments

Lean production and logistics processes were developed in the commercial sector to reduce total system costs of production while simultaneously providing high levels of customer service, increased productivity, and increased worker utilization, In 1993, the Air Force instituted the Lean Logistics program, which successfully implemented some commercial lean principles, enabling a reduction in the total reparable asset material requirement for the Air Force reparable asset pipeline. The Air Force is attempting to further implement lean production principles into depot repair in hopes of further enhancing reparable asset pipeline cost and customer service performance. However, the failure of reparable assets, which determines demand for Air Force depots can be extremely erratic and difficult to predict. A primary criticism of lean systems is their vulnerability in volatile demand environments. Therefore, the implementation of a full-scale lean approach to depot repair may not be conducive to operational success, The purpose of this research is evaluate whether the Air Force reparable pipeline operating under lean production and logistics principles can effectively support operational requirements in various demand environments. In an attempt to answer the research objective, multiple Arena simulation models of a lean reparable asset pipeline operating under various conditions were developed. A full factorial experimental design was employed and multivariate analysis of variance (MANOVA) was utilized to assess the effects of differing levels of demand variability, base and depot supply levels, and the use of premium transportation on cost and stockage effectiveness response variables

Determining Kanban Size Using Mathematical Programming and Discrete Event Simulation for a Manufacturing System with Large Production Variability

In order to become more competitive and aggressive in the market place it is imperative for manufacturers to reduce cycle time, limit work-in-process, and improve productivity, responsiveness, capacities, and quality. One manner in which supply chains can be improved is via the use of kanbans in a pull production system. Kanbans refer to a card or signal for productions scheduling within just-in-time (JIT) production systems to signal where and what to produce, when to produce it, and how much. A Kanban based JIT production system has been shown to be beneficial to supply chains for they reduce work-in-process, provide real time status of the system, and enhance communication both up and down stream. While many studies exist in regards to determining optimal number of kanbans, types of kanban systems, and other factors related to kanban system performance, no comprehensive model has been developed to determine kanban size in a manufacturing system with variable workforce production rate and variable demand pattern. This study used Stewart-Marchman-Act, a Daytona Beach rehabilitation center for those with mental disabilities or recovering from addiction that has several manufacturing processes, as a test bed sing mathematical programming and discrete event simulation models to determine 2 the Kanban size empirically. Results from the validated simulation model indicated that there would be a significant reduction in cycle time with a kanban system; on average, there would be a decrease in cycle time of nine days (almost two weeks). Results were discussed and limitations of the study were presented in the end

Simulation of a milk run material transportation system in the semiconductors industry

This paper deals with a project that consisted in the implementation of a Milk Run Lot Transportation System in Qimonda Porto Test Area, done by a multidisciplinary team formed by Qimonda Porto's workers, and the development of the corresponding simulation model. The first part of the study concerns an industrial engineering assessment of the test area, which identified sources of waste and improvement possibilities, and the implementation process of a Milk Run system in this area. Secondly, the results of the system implementation are discussed, and the construction of a simulation model in Arena® is presented. The purpose of the simulation exercise is to test different system configurations that may allow the improvement of the real-world system. Finally, some information about the simulation results and further steps to be taken regarding the improvement of the system is presented. The target of the project, framed in a Lean approach, was to reduce waste, namely transportation waste, thus optimizing the utilization of the test area human resources.info:eu-repo/semantics/publishedVersio

Designing a robust production system for erratic demand environments.

Production systems must have the right type of material in the right quantities when required for production. They must minimize the work in progress while ensuring no stock-outstock-out occurs. While these twin opposing goals are achievable when demand is stable, they are difficult to realize under an erratic demand pattern. This dissertation aims to develop a production system that can meet erratic demands with minimal costs or errors. After a detailed introduction to the problem considered, we review the relevant literature. We then conduct a numerical analysis of current production systems, identify their deficiencies, and then present our solution to address these deficiencies via the ARK (Automated Replenishment System) technique. This technique is applied to a real-world problem at Methode Engineering ©. We conclude by detailing the scientific benefit of our technique and proposing ideas for future research

SimLean: a reference framework for embedding simulation in lean projects

The intense global competition in today’s market is forcing organisations to looking for good process improvement techniques constantly. Currently lean methodology is one of the most popular programs for process improvement. However, the static lean tools have caused problems in lean implementation. The main aim of the research work is to develop a reference framework about embedding simulation in lean projects. By embedding simulation method in lean projects, deficiencies of static lean tools such as their inability to assess the effects of variation, to validate effects of proposed changes before implementation, to identify other possible improvements or to capture the interactions between system components (Standridge and Marvel, 2006) might be overcome. A combination of research methodology approaches is adopted. This includes conducting literature review, observing companies’ practices and interviewing experts, and adopting several case studies. The focal points of the reference framework are designed in the preimplementation stage of lean projects. Referring to the detailed implementation of the framework, a new modelling environment is proposed. This new environment will use customised VSM templates built in Microsoft Visio software and in Arena simulation system respectively to achieve the quick modelling for lean projects. The proposed modelling environment is validated through five case studies. The main features of the proposed framework are summarized as systematic, generic and the ability to overcome major challenges. A major contribution of the developed system is its ability to simplify, facilitate and standardize simulation modelling in lean projects. It dramatically reduces building blocks in the model, saves model constructing time and eliminates errors in logic design; the simulation models provides better results than static VSM; meanwhile, the interface between Arena and Visio greatly reduces users’ fear for complex simulation modelling environment, and increases the ease of use

Production line: effect of different inspection station allocation under accepts reject inspection policy

Manufacturing system is one of the most important parts in any organization as it produces the output of the company which will generate the profit. It consists partly of the production line which plays the role as the centre of production to create the end product which could be half finished or the full product. It is a big problem for the company to determine which is the better arrangement and combination of the tools or machines available in this area of the organization as different combination will greatly impact the productivity of the production line together with the profit of the company. This research intend to analyze a new production line in a metal stamping company based on the complain from the company and try to explore the better layout or arrangement in the production line in reflect to the complained problem and constrain of the provided of accept the defect and repair inspection policy. The production line is first being analyzed in response to complain through computer simulation. After the problem had been identified, the researcher tried different alternatives in the attempt to seek for the better layout or arrangement in the production line. The effect of different inspection station allocation layout is then being evaluated in term of the production time. The research has resulted in the finding of the cause for the long production time in the factory which is the long inspection steps which consumed much of the production time. After a few alternatives have been explored in allocating the inspection station, it is obvious that the current approach of the production line is the better one. Even by reducing the number of inspection station, interesting enough, the production time does not seem to decrease but yet increased. This finding contradicts the normal thought of fewer stations means shorter time. This finding could be the founding basic in the future research regarding the allocation of the inspection station following certain provided policy. This is also very helpful in real life practice in company as to help them improve their production time. As for the time being, there is yet a research addressing this issue pertaining the given inspection policy

Measuring The Effect Of Erratic Demandon Simulated Multi-channel Manuf

To handle uncertainties and variabilities in production demands, many manufacturing companies have adopted different strategies, such as varying quoted lead time, rejecting orders, increasing stock or inventory levels, and implementing volume flexibility. Make-to-stock (MTS) systems are designed to offer zero lead time by providing an inventory buffer for the organizations, but they are costly and involve risks such as obsolescence and wasted expenditures. The main concern of make-to-order (MTO) systems is eliminating inventories and reducing the non-value-added processes and wastes; however, these systems are based on the assumption that the manufacturing environments and customers\u27 demand are deterministic. Research shows that in MTO systems variability and uncertainty in the demand levels causes instability in the production flow, resulting in congestion in the production flow, long lead times, and low throughput. Neither strategy is wholly satisfactory. A new alternative approach, multi-channel manufacturing (MCM) systems are designed to manage uncertainties and variabilities in demands by first focusing on customers\u27 response time. The products are divided into different product families, each with its own manufacturing stream or sub-factory. MCM also allocates the production capacity needed in each sub-factory to produce each product family. In this research, the performance of an MCM system is studied by implementing MCM in a real case scenario from textile industry modeled via discrete event simulation. MTS and MTO systems are implemented for the same case scenario and the results are studied and compared. The variables of interest for this research are the throughput of products, the level of on-time deliveries, and the inventory level. The results conducted from the simulation experiments favor the simulated MCM system for all mentioned criteria. Further research activities, such as applying MCM to different manufacturing contexts, is highly recommended

A review on equipment protection and system protection relay in power system

Power system equipment is configured and connected together with multiple voltage levels in existing electrical power system. There are varieties of electrical equipment obtainable in the power system predominantly from generation side up to the distribution side. Consequently, appropriate protections must be apt to prevent inessential disturbances that lead to voltage instability, voltage collapse and sooner a total blackout took place in the power system. The understanding of each component on the system protection is critical. This is due to any abnormal condition and failure can be analyzed and solved effectively due to the rapid changing and development on the power system network. Therefore, the enhancement of power quality can be achieved by sheltering the equipment with protection relay in power system. Moreover, the design of a systematic network is crucial for the system protection itself. Several types of protective equipment and protection techniques are taken into consideration in this paper. Hence, the existing accessible types and methods of system protection in the power system network are reviewed

A review on equipment protection and system protection relay in power system

Power system equipment is configured and connected together with multiple voltage levels in existing electrical power system. There are varieties of electrical equipment obtainable in the power system predominantly from generation side up to the distribution side. Consequently, appropriate protections must be apt to prevent inessential disturbances that lead to voltage instability, voltage collapse and sooner a total blackout took place in the power system. The understanding of each component on the system protection is critical. This is due to any abnormal condition and failure can be analyzed and solved effectively due to the rapid changing and development on the power system network. Therefore, the enhancement of power quality can be achieved by sheltering the equipment with protection relay in power system. Moreover, the design of a systematic network is crucial for the system protection itself. Several types of protective equipment and protection techniques are taken into consideration in this paper. Hence, the existing accessible types and methods of system protection in the power system network are reviewed