Kanban, MRP, and shaping the manufacturing environment

Article Abstract:

Japanese approaches to manufacturing, such as the 'kanban' system, are shown to perform exceptionally well in certain US plant environments, as do some more traditional US systems. Simultaneous reduction of setup times and lot sizes is the most effective approach to better customer service and inventory control. Yield rates and worker flexibility are shown to be particularly important shop factors. Product structure and degree of product standardization also affect the efficiency of the manufacturing systems studied. Factor settings such as inaccurate inventory records, equipment failures, and vendor reliability were shown to be less critical than previously believed.

Models

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Kanban controlled pull systems: an analytic approach

Article Abstract:

The operational control difficulties associated with implementing a kanban controlled just-in-time manufacturing system are addressed with the development of a general N-stage serial production model system which is modeled as a discrete Markov process. The system model includes capacity constraints, demand variability, and stochastic machine reliability. Results of the analysis of the system model reveal that incremental improvement can be achieved by lowering the inventory level and increasing machine reliability.

Markov processes

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A dynamic lot-size model with make or buy decisions

Article Abstract:

A dynamic lot-size model with make-or-buy decisions is examined. The production level may not go over a given capacity in each period, but the purchase is unrestricted. The major concern is to find a minimum-cost purchase and production schedule that satisfies the demands over T periods. The solution presented is an O(T to the fifth power) algorithm for stationary production capacities. The results are also extended to other cases such as: bounded inventory; backlogging; and capacitated purchase.

Make-or-buy decisions, Make or buy decisions

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