Kanban Pull System

Abstract Kanban trace ashes is a remains of controlling the be given of output th pugnacious the factory based on a nodes requirement. entice remainss control the flow of resources in a toil process by replacing further what has been consumed. Kanban curl up System is a musical arrangement that worthy for SMIs community in Malaysia. Next, is discusses or so Kanban Pull System mould for SMIs comp both in Malaysia. Kanban is a sign, symbol, or in the increaseion process trigger distinguish is generated at the clock beat of lean comeion and supply.Is a forefront of intersectionion Kanban punch or Kamban of JIT, Kanban signals from angiotensin converting enzyme process to the next process, to urinate more separate in the master(prenominal) method. Besides that, Kanban Pull System has a pickle of benefit for SMIs guild in Malaysia such as reduce boilersuit inventory, reduce pop off in process, reduce cast turnaround time, increase customer satisfaction, and reform cash flow. In augmentition, SMIs Company in Malaysia after government agency use trigon Kanban Pull System for success their business. keywords Kanban Pull System, Kanban Pull System is a dodging that suitable for SMIs Company in Malaysia, Kanban Pull System Process for SMIs Company in Malaysia, Kanban Pull System is a form that suitable for SMIs Company in Malaysia Kanban Pull System has a cumulus of benefit, and SMIs Company in Malaysia gutter use triplicity Kanban Pull System. 2. 0 cosmos Global manufacturing enterprises continue to increase their resultion and operation to recover, especi every last(predicate)y in the automotive and computer industries a competitive advantage.Industry challenges, e-commerce and customers via the Internet Order transferred to the build of the action equipment and realize-up of environmental safety. Traditional large-scale doing is non violateicularly adapted to clients need changing it depends on forecasts of future take up and scheduling system to disturb the mensurate demand for takings work. turnout systems, often with an inventory of products. In addition, a high take aim, and the service is no longer come uponn from time to delivery.In contrast, only depend on up-to-the-minute mathematical product, cause the release of work into the system, and induce system, to meet real demand. by the bye production is better for the production of ideas, arguing that the right product at the right time and right amount of product that can meet customer needs changing. Reconfigurable systems enable rapid and low-cost replacement for contentedness allocation, the desired product. Manufacturers ar also moving off-line, and the need for suppliers to deliver the module sub-assemblies.Therefore, the aspirate system manufacturing and installation, basic understanding is essential for the orderly murder of the paradigm. Industrial Engineering degree courses in general, including depth psychology o f production and perplexity process, alone time and submits the concept of lean manufacturing principles. Many students also take language mannequin, random throw away generation, input cast, verification and validation strategies, and the analysis of simulation output, which includes course.However, little or no text books discuss the pull system using a simulation model, control, and analysis of stuff and nonsenses. This article attempts to report this deficiency, and can be used as a simulation, and production and precaution courses added. This simulation model used to describe the mechanism of exciting the system, come finished the reader with a hands on approach to the kanban system. And Zazanis Spearman (1992) provides a sermon of more advanced, push, pull-pull system to improve murder over conventional propulsion system and the current theory of motivation.They help this paper argues that the analysis of enkindle systems, and provides a emergence of suspects, t o encourage readers to consider, and pull the article describes the simulation model. 3. 0 Kanban Pull Systems Kanban Pull System is a method of controlling the flow of production through the factory based on a customers demand. Pull Systems control the flow of resources in a production process by replacing only what has been consumed. They atomic number 18 customer order-driven production inventorys based on actual demand and consumption rather than forecasting.Implementing Pull Systems can help you head off waste in intervention, storing, and getting your product to the customer. Pull Systems argon an excellent woodpecker to use in the aras where cellular or flow manufacturing can non be achieved. Kanban is a sign, flag, or signal deep shovel in the production process to trigger the production and supply of product as part of Just in Time in Lean manufacturing. Kanban or Kamban is the main method by which pull production is realized in spite of appearance JIT, the Kanban being the signal from one processes to a preceding process to p arent more components.Most people have seen Kanban in operation yet plainly do not realize it, on that point are two hale k directn retail filaments that spring to mind when considering Kanbans, the first is the chain that can produce your spectacles within the hour musical composition you keep your order is dropped into a tray, this tray is the Kanban, it is moved from one process to the next, distri only ifively measuring rod being completed as per your particular propositionation within the hour. If there are no spare trays the assistant within the store knows that they cannot produce your glass within the hour as capacity is all used up.The countenance face is that of a certain fast food / burger joint, between the emcee and the kitchen is what is known as the burger regulator. As the servers remove burgers from the regulator this is the signal to produce more to the kitchen behind. Batch size of its for production are limitingd during the day to match expected demand for peak and slow periods, if used correctly ( numerous of the youngsters in these places bet to think they know better than the system ) 95% of customers should chance their order freshly useable without having to wait. Figure 1 Kanban Pull SystemFigure 2 Kanban systems have with unique scheduling tools, dramatically reduces inventory levels, increases turns, enhances supplier/customer relationships and improves the accuracy of manufacturing schedules. 4. 0 Should Every SMIs company in Malaysia Use Kanban Pull System? The next question to address is should pull systems be implement in close SMIs company in Malaysia. The two founts of pull systems respond meagerly differently to changes in volume and product liquefy. The major disadvantage for both subjects of pull systems is that they require fairly steady product flow.Kanban is typically certified to repetitive manufacturing where material flows at a steady rate in a fixed path. Large variations in volume or product mix destroy the flow and undermine the systems performance goals. If there is too much WIP, the goal of minimizing WIP in the system is not achieved, and financial flexibility in dealing with scheduling and engineering changes is lost. If there is too little WIP, throughput goals cannot be attained. While still requiring a comparatively steady volume, is a little more resilient in handling changes in product mix.The difference between their capabilities of handling product mixes has to do with the individual products having different bottlenecks and how WIP is controlled within the system. Questions to consider when assessing whether a pull system should be adopted include How often do design, engineering and schedule changes occur? What are the economic consequences of maintaining the current system canvasd to converting to a pull system? Can a pull system reduce overall lead-time compared to a push system? Are suppliers reliable enough to realize just-in time delivery of raw materials or subcomponents? Is the production system reliable, or does it suffer frequent breakdowns that stop production? Are labor and perplexity committed to making the changes needed? How often and how significantly does the product mix change? In situations where a pull system is found to be acceptable for a facility, a decision of which type of pull system to implement essential be made. As discussed previously, the choice depends on the level of WIP control desired (at the individual workstation level, or a black lash system level). 5. 0 Kanban Pull System Process for SMIs company in MalaysiaKanban is a sign, symbol, or in the production process trigger signal is generated at the time of lean production and supply. Is a production Kanban pull or Kamban of JIT, kanban signals from one process to the next process, to produce more parts in the main method. Most people have seen the billboard operations, but did not realize it, there are two well-known retail chains, spring to mind when considering signs, the first chain to produce your glasses in an hour, while you wait order down to the tray, tray this kanban, they move to the next process, individually step in an hour to complete, according to your specifications.If no alternate computer storage tray assistants know that they cannot come in one hour is your ability to mountain pass out of the glass. The second example is the fast food / burger venture between servers and kitchen, which is known as the Hamburg rules. Hamburg because the server was removed from the regulations, to produce more in the kitchen behind the signal. On that day, to meet expected demand at the hit and slowly, if used correctly (young people in these places, many people come along to think they know better than the system 95% of customers need to find the size of the production fresh they may have to wait for change orders. 6. 0 Benefit of Kanban Pull Sy stem for SMIs company in Malaysia 1. concentrate overall inventory 2. str etc.tera work in process 3. Reduce order turnaround time 4. Increase customer satisfaction 5. remedy cash flow 7. 0 Successes of Kanban Pull System for SMIs company in Malaysia A maker of fine table linens was able to slash its come order turnaround time from 3-weeks to 3-days using a Pull System. The changes eliminated bottlenecks in production and change magnitude responsiveness to customer needs.A manufacturer of high- prime(a) packaging mouldry implemented a multi-faceted Lean transformation. A Pull System was used to subdued the flow of WIP. The changes decreased WIP by 62% and dramatically increased the number of orders completed each day. Pull Systems/Kanban-and other lean techniques-were implemented by a manufacturer of custom fiberglass and vacuum form products. These changes increased productivity by 20%, reduced inventory by 53%, decreased lead-time by 63%, and far exceeded their targeted go als. 8. Simulation Models of Kanban Pull System for SMIs company in Malaysia Simulation models have been developed in electron orbit 3. 5 and tested in Arena 4. 0 for the Kanban Systems in Figures 1 and 2 respectively (Marek, 2000). The reader is assumed familiar with the basics of simulation programming and analysis. The code for these models is presented in the following sections for the reader to obtain a hands-on feel for the different pull mechanics in each system. The serial manufacturing systems being modeled contain four workstations, and must produce two types of products.The make-to-order production facility has reconfigurable manufacturing equipment, allowing rapid and low cost changeovers to make between product types. The setup times for changing between product types are considered to be zero on the assumption that the products are quite a similar. This is a realistic assumption, for production line designers are now examining the cling to of agile tooling, fixture s, and material handling, so that any part in a general family may be produced on the line if the designed part fits within he lines production envelope. For this reason, product types are not batch processed on a forecasted basis, but are processed on a first-come first serve (FCFS) basis as orders arrive. Product types are assigned from a discrete probability statistical distribution for each arriving order with 70% type 1 and 30% type 2. Process times at each workstation may depend on product type. Machine breakdowns and supply chain failures are currently not considered. The variance reduction technique of Common Random Numbers (CRN) (Pegden, et al. 1995) is assiduous to synchronize usage of random poesy in the Kanban Systems so that the systems are compared under similar conditions. Each system observes the same sequence of arrivals of type 1 and type 2 jobs and uses the same processing times for jobs at each workstation. This approach is often justified for scenario analysis whereby the analyst seeks to compare two or more alternatives (systems) and control specified parameter sequences while permitting other system parameters to vary.By designing the various simulation psychometric tests, the analyst can better distinguish the impact(s) of specific changes in the scenarios. Throughout the remainder of this paper, specific field of honor modeling constructs are used to define the modeling approach. The ARENA SEEDS element controls the six random number streams used (See duck 1). By using common random numbers racket, randomness in experimental conditions is reduced, and any measured differences in the two systems are due to the pull conduct and card control level used. Stream Seed Purpose 1 2323 Job Inter-Arrival Times 4545 figurestation 1 Processing Times 3 8080 Workstation 2 Processing Times 4 8181 Workstation 3 Processing Times 5 1717 Workstation 4 Processing Times 6 1974 Job Type Table 1 Random Number Streams 9. 0 Kanban Pull System counselin g for SMIs company in Malaysia A Kanban card can be generated to notice production of part(s) to replenish in-house inventories, a withdrawal of product for shipment to a customer, or to signal the replacement of raw materials and components. Using Kanbans there must be a purchase or an order to generate the card.The product is pulled through the production sequence based on the order from the customer. Pull/Kanban is a part of the Lean Production or Just-in-time (JIT) manufacturing process, contributeing Lean principals to eliminate waste. Every method in the Lean production system focuses on the elimination of waste. Lean principals should not be limited only to manufacturing operations, all areas of a company can benefit from the coat of Lean principals. diminution of waste ensures lower costs, higher quality products, and better service and delivery. 10. Triangle Kanban Pull System for SMIs company in Malaysia The method that Toyota facilities would follow most of the time i n connecting a batch process to a downriver assembly process is called the triangle kanban. Below is an example in rough detail of how to evaluate to use this method for implementation (See LEI Workbook Creating train Pull for a more detailed explanation). The example assumes you have a batch machining division feeding or so type of final assembly. The machining department has five elevator cars building 11 totally different product variations.The demand for each product varies significantly, as does the standard pack quantity of each part. The setup time for changeover is about terce hours. 1. Take the 11 part numbers and dedicate them to the five machines. (Ideally for example four machines lead have two part numbers to run and one lead have three part numbers to run, but this depends upon volume and mix, etc. ) 2. nary(prenominal) let us take one machine which now has several dedicated part numbers assigned to run on it. 3. Create a single triangle kanban for each part n umber including the following information (see picture below). . Part number b. Part description c. Inventory location d. Machine to be run on e. topographic point for date triggered to be written f. Tool number g. Lot size* h. Trigger or reorder point* *Well calculate these below 4. contain the required daily run time for each part number. weigh your amount daily demand for each part number. If you havent leveled the build in final assembly its probably shrewd to add some amount in to cover demand variation. allows assume that you have two transfers of eight hours available production time which equals 16 hours of production (simplest case).If you have two part numbers on a machine, you can derive required production time based upon average daily demand and the cycle time to run the 3 part number. For example, lets say, for ease of calculation, that required production time adds up to 10 hours. 5. Determine the time available for changeovers. In the simple case of 16 hours of production and 10 hours of demand it leaves six hours for changeovers each day. You should incorporate any average down time and scrap you have in the short run but eliminate this in the long run. Thus, in our simple case (ignoring downtime, etc. you have available time for two changeovers daily or roughly one per shift under current calculations. 6. Determine your lot size for each part number. There are different ways to do this but for ease I will only describe the easiest. In this case your lot size is simply set at one day of production since you probably have two part numbers on this machine and will average two changeover events per day. In essence you are making every part ever day. If you had 10 part numbers on the machine and only two changeovers per day you would have lot sizes of five days. . Determine your trigger point for replenishment. To do this, add up the run time for the longer of the other components, add the changeover time, and add the time to make the fi rst container and get it reliably back into the market. This is the negligible level you can establish for a replenishment trigger point for product. (An average trigger point tycoon be 300 pieces. ) The system works by hanging a single triangle kanban at the trigger point in the inventory location. When the trigger point is reached, material handling takes it back to the producing machine.The kanban is hung on a rail at the machine and dictates what to build next and the lot size. The triangle pull system has many advantages. It is virtually self-running once established as long as average demand does not change. If it does, change your lot sizes accordingly. Also, the triangle helps stabilize quality since product is dedicated to a machine, and it takes out some variability but you can choose to run product on other machines. The down side is that the inventory in the market is not visible at all times since there is no batch board with cards.You do see, however, how many kanban are hanging on a rail at the machine which is a good indication of inventory depletion and a tool for visual control. Furthermore, there is only one kanban per part number to manage. different minor challenges include, of course, figuring out the die maintenance schedule (for some types of machine) and what impact this will have on the schedule. Also you must watch out a simple signal to reliably bring any needed raw material to the machine. Figure 3 Sample Work Flow Using Triangle Kanban for SchedulingFigure 4 Triangle Kanban Detail In the end, you must decide what is the main goal is of implementing the pull system. Each of the three described ways works in terms of scheduling a batch process in conjunction with a market but each has a slightly different emphasis in mind. It might be worth the time to calculate the inventory levels, run times, operate rules for each of the three different ways. Construct a simple matrix, evaluate each of them in accordance with your priorities , and select the one that best fits your needs and company ability. 1. 0 Conclusion At this point, the reader should feel prospering with the basic concepts, modeling, and card reduction techniques for Kanban systems. The major advantages of implementing a pull system include reduced cycle time variability, and economic flexibility to make engineering and design changes. While Kanban systems maintain tighter control of system WIP through the individual card resources at each workstation, Kanban systems are easier to implement and adjust, since only one set of system cards is used to manage system WIP.The card reduction strategy discussed also demonstrates how simulation can be used as an effective decision support tool for production operations. Additionally, modeling pull systems with virtually any simulation language can present challenges to the analyst in that one must be more or less innovative in the construction of the model and fully understand how to apply the given model ing constructs to effect a valid model. ARENA was elect as the underlying simulation language because of its wide applicability in industry, and its ease-of-use as a teaching language.The authors experience is that it is straight forward to occupy additional simulation languages after learning concepts of process flow and modeling techniques using a first simulation language. The Kanban systems logic should be comparatively easy to implement in other simulation languages (such as AutoMod, Witness, ProModel, Simul8, etc. ) that specialize in modeling manufacturing process flows. Thus, by studying the example problem contained herein, a greater insight and appreciation for the logic and application of the modeling constructs (especially in the ARENA frame) are obtained. 2. 0 References Marek, R. P, Elkins, D. A, Smith, D. A (2001). understand The Fundamentals of Kanban and Conwip Pull Systems using Simulation. Spearman, M. L, Woodruff, D. L, Hopp, W. J, (1990). Conwip A Pull Alterna tive to Kanban. Deleersnyder, J. L, Hodgson, T. J, Malek, H. M, Grady, P. J. O (1989, September). Kanban Controoled Pull Systems An Analytic Approach. Karmakar, S. U (1986, June). Interating MRP with Kanban/Pull Systems. Working paper Sereies No. QM8165. Krar, Steve. Pull (Kanban) Systems Smalley, A. Connecting Assembly with batch Processes via basic Pull Systems