Overview of Kanban systems

The just-in-time (JIT) approach to manufacturing control with 'Kanbans' has received much attention in the last decade. The Kanban systems efficiently control repetitive manufacturing environments and offer simplicity. However, they are not suitable for non-repetitive manufacturing systems. The research approaches applied to Kanban systems include simulation, mathematical, and stochastic approaches, with the emphasis on analysing characteristics of Kanban systems, determining the optimal number of Kanbans, and comparing Kanban systems. In this paper, an overview of different Kanban systems, methodologies, and alternatives to the pure Kanban systems are discussed. The basic Toyota Kanban system is introduced. The recently developed methodologies for Kanban systems are surveyed. The Kanban approach is illustrated with the case studies. This paper offers a broad discussion of Kanban systems and classifies the previous studies. Several conclusions are drawn and suggestions for further research are given.

[1]  Y. Sugimori,et al.  Toyota production system and Kanban system Materialization of just-in-time and respect-for-human system , 1977 .

[2]  J. Miltenberg,et al.  Level schedules for mixed-model assembly lines in just-in-time production systems , 1989 .

[3]  Mitsutoshi Kojima,et al.  Optimal numbers of two kinds of kanbans in a JIT production system , 1995 .

[4]  Loren Paul Rees,et al.  A comparative analysis of an MRP lot-for-lot system and a Kanban system for a multistage production operation , 1989 .

[5]  Mark L. Spearman,et al.  Customer Service in Pull Production Systems , 1992, Oper. Res..

[6]  R. B. Chase Production And Operations Management: A Life Cycle Approach , 1973 .

[7]  門田 安弘,et al.  Toyota production system : practical approach to production management , 1983 .

[8]  Ian Graham Comparing trigger and kanban control of flow-line manufacture , 1992 .

[9]  Loren Paul Rees,et al.  Dynamically Adjusting the Number of Kanbans in a Just-in-Time Production System Using Estimated Values of Leadtime , 1987 .

[10]  Andrew B. Whinston,et al.  Towards an adaptive Kanban system , 1990 .

[11]  Peter O'Grady,et al.  Kanban controlled pull systems: an analytic approach , 1989 .

[12]  Bhaba R. Sarker,et al.  The effect of imbalance in a just-in-time production system: a simulation study , 1988 .

[13]  Blair J. Berkley Effect of buffer capacity and sequencing rules on single-card kanban system performance , 1993 .

[14]  Debasis Mitra,et al.  Analysis of a Kanban discipline for cell coordination in production lines , 1990 .

[15]  Ahmet Şatir,et al.  Kanban-based operational planning and control: simulation modelling , 1995 .

[16]  S. Axsäter,et al.  Installation vs. echelon stock policies for multilevel inventory control , 1993 .

[17]  M. C. Jothishankar,et al.  Determination of optimal number of Kanbans using stochastic petri nets , 1992 .

[18]  Kut C. So,et al.  Allocating buffer storages in a pull system , 1988 .

[19]  C. Kraft Dynamic Kanban semiconductor inventory management system , 1992, IEEE/SEMI Advanced Semiconductor Manufacturing Conference and Workshop - ASMC '92 Proceedings.

[20]  Amrik S. Sohal,et al.  INTEGRATING CNC TECHNOLOGY AND THE JIT KANBAN SYSTEM: A CASE STUDY , 1993 .

[21]  Y. Monden Toyota Production System: Practical Approach to Production Management , 1983 .

[22]  Lee J. Krajewski,et al.  Kanban, MRP, and Shaping the Manufacturing Environment , 1987 .

[23]  Ronald G. Askin,et al.  Production planning for a multi-item, single-stage kanban system , 1994 .

[24]  Yves Dallery,et al.  A unified modeling of Kanban systems using petri nets , 1991 .

[25]  Milton L. Smith,et al.  Increasing the production rate of a just-in-time production system with variable operation times , 1988 .

[26]  R. Schonberger Japanese Manufacturing Techniques , 1982 .

[27]  Gabriel R. Bitran,et al.  A mathematical programming approach to a deterministic Kanban system , 1987 .

[28]  Hiroshi Ohta,et al.  An optimal operation planning for the fixed quantity withdrawal Kanban system with variable leadtimes , 1994 .

[29]  Lawrence Zeidner,et al.  Designing a Kanban manufacturing system using the server network generator (SNG) CASE tool , 1991, APL '91.

[30]  Hiroshi Ohta,et al.  The optimal operation planning of a Kanban system with variable lead times , 1994 .

[31]  S. Elmaghraby The Economic Lot Scheduling Problem (ELSP): Review and Extensions , 1978 .

[32]  Richard J. Schonberger Applications of Single-Card and Dual-Card Kanban , 1983 .

[33]  S. Sethi,et al.  A Note on "Level Schedules for Mixed-Model Assembly Lines in Just-in-Time Production Systems" , 1991 .

[34]  Paul H. Zipkin Computing Optimal Lot Sizes in the Economic Lot Scheduling Problem , 1991, Oper. Res..

[35]  M. C. Jothishankar,et al.  Metamodelling a Just‐in‐time Kanban System , 1993 .

[36]  Robert E. Tarjan,et al.  One-Processor Scheduling with Symmetric Earliness and Tardiness Penalties , 1988, Math. Oper. Res..

[37]  Bhaba R. Sarker Simulating a just-in-time production system , 1989 .

[38]  Marc Gravel,et al.  Modeling the Performance of Kanban Assembly Shop , 1993 .

[39]  Gabriel R. Bitran,et al.  An optimization approach to the Kanban system , 1985 .

[40]  Wayne J. Davis,et al.  Configuring a Kanban system using a discrete optimization of multiple stochastic responses , 1987 .

[41]  Richard Schonberger,et al.  World class manufacturing : the lessons of simplicity applied , 1986 .

[42]  P. Glasserman,et al.  Monotone Structure in Discrete-Event Systems , 1994 .

[43]  Marc Gravel,et al.  Using the Kanban in a job shop environment , 1988 .

[44]  Yuehwern Yih,et al.  Determining the number of kanbans and lotsizes in a generic kanban system : a simulated annealing approach , 1994 .

[45]  Debasis Mitra,et al.  Analysis of a Kanban Discipline for Cell Coordination in Production Lines, II: Stochastic Demands , 1991, Oper. Res..

[46]  B. J. Berkley,et al.  Tandem queues and kanban-controlled lines , 1991 .

[47]  Shigeo Shingo,et al.  The Sayings of Shigeo Shingo: Key Strategies for Plant Improvement , 1987 .

[48]  P. J. Weeda,et al.  A framework for quantitative comparison of production control concepts , 1989 .

[49]  David L. Woodruff,et al.  CONWIP: a pull alternative to kanban , 1990 .

[50]  A. A. Pervozvanskiy,et al.  A kanban system as a manufacturing control system with feedback , 1994 .

[51]  Yuehwern Yih,et al.  Generic kanban systems for dynamic environments , 1994 .

[52]  S. Tayur Structural properties and a heuristic for kanban-controlled serial lines , 1993 .

[53]  Mahesh Gupta,et al.  A system dynamics model of a JIT-kanban system , 1989 .

[54]  Richard C. Vaughn Introduction to industrial engineering , 1967 .

[55]  Maling Ebrahimpour,et al.  Dynamic Simulation of a Kanban Production Inventory System , 1985 .

[56]  松井 正之 Batching Policy in Kanban Systemsについて(特別セッション(2)ジャスト・イン・タイム生産システム) , 1994 .

[57]  大野 耐一,et al.  Toyota production system : beyond large-scale production , 1988 .

[58]  James F. Cox,et al.  An examination of just-in-time management for the small manufacturer: with an illustration , 1986 .

[59]  Hsu-Pin Wang,et al.  Determining the number of kanbans: a step toward non-stock-production , 1990 .

[60]  Daniel Sipper,et al.  JIT vs. WIP— a trade-off analysis , 1989 .

[61]  S. Otenti A modified Kanban system in a semiconductor manufacturing environment , 1991, [1991 Proceedings] IEEE/SEMI Advanced Semiconductor Manufacturing Conference and Workshop.

[62]  John N. Petroff Handbook of Mrp II and Jit: Strategies for Total Manufacturing Control , 1993 .

[63]  Chao-Hsien Chu,et al.  Simulation studies in JIT production , 1992 .

[64]  Samia M. Siha The pull production system: modelling and characteristics , 1994 .

[65]  Osamu Kimura,et al.  Desiǵn and analysis of Pull System, a method of multi-staǵe production control , 1981 .

[66]  Loren Paul Rees,et al.  An investigation of the factors influencing the number of Kanbans required in the implementation of the JIT technique with Kanbans , 1987 .

[67]  Ahmet Satir,et al.  A kanban-based simulation study of a mixed model just-in-time manufacturing line , 1995 .

[68]  D. W. Cheng Concavity of system throughput and information transfer in a PAC system , 1993, Oper. Res. Lett..

[69]  J. A. Buzacott,et al.  Queueing models of Kanban and MRP controlled production systems , 1989 .

[70]  Shigeo Shingo,et al.  Non-Stock Production: The Shingo System for Continuous Improvement , 1988 .

[71]  P. Glasserman,et al.  Monotone Structure in Discrete Event Systems. , 1995 .

[72]  Henry C. Co,et al.  A dynamic programming model for the kanban assignment problem in a multistage multiperiod production system , 1991 .

[73]  N. Singh,et al.  The Development of a Kanban System: A Case Study , 1990 .

[74]  Jonathan F. Bard,et al.  Determining the number of kanbans in a multiproduct, multistage production system , 1991 .

[75]  R. R. Inman,et al.  Sequencing JIT mixed-model assembly lines , 1991 .

[76]  Loren Paul Rees,et al.  A SIMULATION ANALYSIS OF THE JAPANESE JUST‐IN‐TIME TECHNIQUE (WITH KANBANS) FOR A MULTILINE, MULTISTAGE PRODUCTION SYSTEM , 1983 .

[77]  Bhaba R. Sarker,et al.  The performance of push and pull systems: a simulation and comparative study , 1989 .

[78]  Jan Olhager,et al.  An integrated push-pull manufacturing strategy , 1990 .

[79]  O. Geoffrey Okogbaa,et al.  Maintenance policies in just-in-time manufacturing lines , 1992 .

[80]  Tae-Moon Kim Just-in-time manufacturing system: a periodic pull system , 1985 .

[81]  S. Jordan Analysis and Approximation of a JIT Production Line , 1988 .