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.
| Published in | International Journal of Industrial and Manufacturing Systems Engineering (Volume 7, Issue 1) |
| DOI | 10.11648/j.ijimse.20220701.13 |
| Page(s) | 17-24 |
| Creative Commons |
This is an Open Access article, distributed under the terms of the Creative Commons Attribution 4.0 International License (http://creativecommons.org/licenses/by/4.0/), which permits unrestricted use, distribution and reproduction in any medium or format, provided the original work is properly cited. |
| Copyright |
Copyright © The Author(s), 2022. Published by Science Publishing Group |
Kanban, Discrete-Event Simulation, Optimization, Production Performance
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APA Style
Angassu Girma Mullisa, Walid Abdul-Kader. (2022). Optimal Kanban Number: An Integrated Lean and Simulation Modelling Approach. International Journal of Industrial and Manufacturing Systems Engineering, 7(1), 17-24. https://doi.org/10.11648/j.ijimse.20220701.13
ACS Style
Angassu Girma Mullisa; Walid Abdul-Kader. Optimal Kanban Number: An Integrated Lean and Simulation Modelling Approach. Int. J. Ind. Manuf. Syst. Eng. 2022, 7(1), 17-24. doi: 10.11648/j.ijimse.20220701.13
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Download@article{10.11648/j.ijimse.20220701.13,
author = {Angassu Girma Mullisa and Walid Abdul-Kader},
title = {Optimal Kanban Number: An Integrated Lean and Simulation Modelling Approach},
journal = {International Journal of Industrial and Manufacturing Systems Engineering},
volume = {7},
number = {1},
pages = {17-24},
doi = {10.11648/j.ijimse.20220701.13},
url = {https://doi.org/10.11648/j.ijimse.20220701.13},
eprint = {https://article.sciencepublishinggroup.com/pdf/10.11648.j.ijimse.20220701.13},
abstract = {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.},
year = {2022}
}
TY - JOUR T1 - Optimal Kanban Number: An Integrated Lean and Simulation Modelling Approach AU - Angassu Girma Mullisa AU - Walid Abdul-Kader Y1 - 2022/03/04 PY - 2022 N1 - https://doi.org/10.11648/j.ijimse.20220701.13 DO - 10.11648/j.ijimse.20220701.13 T2 - International Journal of Industrial and Manufacturing Systems Engineering JF - International Journal of Industrial and Manufacturing Systems Engineering JO - International Journal of Industrial and Manufacturing Systems Engineering SP - 17 EP - 24 PB - Science Publishing Group SN - 2575-3142 UR - https://doi.org/10.11648/j.ijimse.20220701.13 AB - 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. VL - 7 IS - 1 ER -
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