Abstract
In this paper we explore the impact of sudden breakdown of the material handling system on the performance of a traditional kanban system (TKS). TKS, which is an element of the just-in-time system, is designed to operate in an ideal environment such as constant processing times and uninterrupted processing. However, in a real life environment, the TKS could be subjected to various unpredictable factors including stochastic processing times and process interruption due to equipment failure. These factors would seriously strain the performance of TKS. We consider a TKS in which some stations are dependent on a material handling system to move parts between them. We study the effect of a sudden breakdown of such a material handling system on the performance of the TKS. In addition, we also study a newly developed kanban system (which dynamically and systematically manipulates the number of kanbans in order to offset the blocking and starvation caused by these factors during a production cycle) under the same conditions. We refer to the new system as the 'flexible kanban system' (FKS). We compare the overall performances of the TKS and FKS by considering a variety of cases. We present the solution procedure, results and discussion for these cases.
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