Abstract
Purpose: The paper aims to present a case study and later simulation analysis on a kanban system that incorporating milk-run operation to draw in raw material to the process. Design/methodology/approach: Data collection at the case study company for ten weeks followed by a process study called value stream mapping. The proposed kanban model is simulated to test its various performances including total output, average flow time, average work-in-process, SME utilization, and average waiting time. Response surface methodology is adopted to generate suitable representative regression models. Findings: For all performance measures, simulation results showed that the proposed system consistently outperforms the push system currently practiced. Second, the system indicates the advantages of leveling, particularly in the event of machine failure and blockage. Third, operator in the proposed kanban system has a lower utilization, even with the additional material handling task. Research limitations/implications: This study only begins to reveal the implication of leveling for production control on multi-machine scenario. The simulation of the system is solely based only the case study. The control parameters critical to the case study, were naturally used. The furtherance of the research should include generalizing the system and devising the respective methodology to facilitate wider applications. Practical implications: Originality/value: The kanban system is proposed in the light of conflicting interests in handling the surface mounting and the related upstream processes. Such aspect is common to electronics assembly industry.
Highlights
The electronics assembly industry has today become increasingly challenging due to rapid technological changes, high material costs, and continuing trend of miniaturization (Tatsiopoulos, Avramopoulos, & Theoharis, 1997)
Lean manufacturing is about removing wastes from activities and processes that have no value-added on the products (Chen & Meng, 2010)
A distinct feature of lean manufacturing is that products are not pushed through the production but are rather pulled by customers (Liker, 2004)
Summary
The electronics assembly industry has today become increasingly challenging due to rapid technological changes, high material costs, and continuing trend of miniaturization (Tatsiopoulos, Avramopoulos, & Theoharis, 1997). A distinct feature of lean manufacturing is that products are not pushed through the production but are rather pulled by customers (Liker, 2004). Along this line, demarcation can be established between push and pull systems. Jobs are queued in the system from entry to exit in order to process a complete product (Bonney, Zhang, Head, Tien, & Barson, 1999). This often entails an excessive amount of inventory, including WIP on the shop floor. The pull system is a method by which jobs are made when there is a request from the succeeding machine, effectively avoids overproduction
Sign-in/Register to view highlights & summary Sign-in/Register to access full text options 
Talk to us
Join us for a 30 min session where you can share your feedback and ask us any queries you have
Schedule a callDisclaimer: All third-party content on this website/platform is and will remain the property of their respective owners and is provided on "as is" basis without any warranties, express or implied. Use of third-party content does not indicate any affiliation, sponsorship with or endorsement by them. Any references to third-party content is to identify the corresponding services and shall be considered fair use under The CopyrightLaw.
