A Framework of e-Kanban System for Indonesia Automotive Mixed-Model Production Line

Penulis Santo Wijaya, Fransisca Debora, Galih Supriadi, Insan Ramadhan
Publisher International Journal of Science and Research (IJSR)
Nomor ISSN 2319-7064

Sari

The paper describes a development framework of e-Kanban (electronic Kanban) system for Indonesia automotive mixedmodel production line. It is intended to solve problems found during the implementation of traditional kanban system in the subjected company. The traditional kanban system posed inefficiencies in the production line and it has been identified in this paper. The impact is significant in causing delay information for production instruction, loss of kanban cards, inaccurate inventory, and other humanrelated errors. We also identified that these inefficiencies are also increasing with the increase of product variety and volume in mixedmodel production line. The presented framework is the extension of the traditional kanban system that has been running for over one year in the subject company. Design framework objective is to handle all the inefficiencies problem occurred and improve the overall efficiency of material and information flow within the production line. It is a combination of paper-based kanban and software-based kanban system. Paper-based kanban handles the movement of man and material in the production line. While software-based kanban system handles kanban lot-sizing control, production instruction schedule, and integration with the subjected company ERP (Enterprise Resource Planning) system. The contribution of this work is an e-Kanban framework system for an in-house production system that employs mixed-model production line.

Teks Lengkap:

PDF

Referensi

Y. Monden, “Toyota production system: an integrated approach to Just-In-Time,” CRC Press, 4th Ed., Florida, 2011.

H. Mariam, E. A. Laila, A. Abdellah, “E-kanban the new generation of traditional kanban system, and the impact of its implementation in the enterprise,” in Proceeding of the International Conference on Industrial Engineering and Operations Management, Rabat, Morocco, pp. 1261-1270, 2017.

C. S. Kumar, R. Panneerselvam, “Literature review of JIT-Kanban system,” International Journal of Advanced Manufacturing Technology, 32(1), pp. 393-408, 2007.

A. Lee-Mortimer, “A continuing lean journey: an electronic manufacturer’s adopting of Kanban,” Assembly Automation, 28(2), pp. 103-112, 2008.

R.A. Inman, R.S. Sale, Jr. K. Green, D. Whitten, “Agile manufacturing: relation to JIT, operational performance and firm performance,” Journal of Operations Management, 4(29), pp. 343-355, 2011.

T. Melton, “ The benefits of lean manufacturing: what lean thinking has to offer the process industries,” Chemical Engineering Research and Design 83(A6), pp. 662-673, 2005.

E. Corona, E. P. Filippo, “A review of lean-kanban approaches in the software development,” WSEAS Transactions on Information Science and Applications, 1(10), pp. 1-13, 2013.

R. Kumar, V. Kumar, “Lean manufacturing: elements and its benefits for manufacturing industry,” in Proceeding of the National Conference on Trends and Advances in Mechanical Engineering, Fariadabad, Haryana, pp. 748-755, 2012.

A. N. Nida, J. Roseleena, H. Nurul, “Design framework of a smart kanban system for Malaysian automotive mixed-model assembly line,” Journal of Scientific Research and Development,” 3(4), pp. 35-41, 2016.

M. Zemczak, D. Krencyzek, “A new procedure of production order sequencing in mixed-model production systems,” Advanced Material Research 1036, pp. 864- 868, 2014.

S. Pedro, R. V. Leonilde, “Cellular manufacturing with kanbans optimization in Bosch production system,” The Romanian Review Precision Mechanics, Optics, & Mechatronics 20(37), pp. 393-410, 2010.

G. Kovac, S. Kot, “Facility layout redesign for efficiency improvement and cost reduction,” Journal of Applied Mathematics and Computational Mechanics, 16(1), pp. 63-74, 2017.

M. T. M. Ramadan, “RFID-enabled dynamic value stream mapping for a smart real-time lean-based manufacturing system,” Dissertation, University of Duisburg-Essen, 2016.

M. Zemczak, D. Krencyzek, “A new procedure of production order sequencing in mixed-model production systems,” Advanced Material Research 1036, pp. 864- 868, 2016.

J. K. Liker, J. M. Morgan, “The Toyota way in services: the case of lean product development,” The Academy of Management Perspectives, 2(20), pp. 5-20, 2006.

J. Majava, T. Ojanpera, “Lean production development in SMEs: a case study,” Management and Production Engineering Review, 2(8), pp. 41-48, 2017.

M. Apreutesei, E. Suciu, I. R. Arvinte, D. Munteanu, “Application of kanban system for managing inventory,” Bulletin of the Transilvania University of Brasov, 3(52), pp. 161-166, 2010.

Y. Dallery, G. Liberopoulos, “Extended kanban control system: combining kanban and base stock,” IIE Transactions, 32, pp. 369-386, 2000.

N. A. A. Rahman, S. M. Sharif, M. M. Esa, “Lean Manufacturing Case Study with Kanban System Implementation,” in Internasional Conference on Economics and Business Research, Kedah, Malaysia, pp. 174-180, 2013.

S. Jarupathirun, A. P. Ciganek, T. Chotiwankaemanee, C. Kerdpitak, “Supply chain efficiencies through eKanban – A case study,” in Int. Conference IEEE, pp. 1092-1096, 2009.

M. R. Naik, E. V. Kumar, B. U. Goud, “Electronic kanban system,” Internasional Journal of Scientific and Research Publications,” 3(3), pp. 1-6, 2013.

B. Vernyi, T. Vinas, “Easing into e-kanban,” Industry Week, 12(254), pp. 32, 2005.

P. Middleton, D. Joyce, “Lean software management: BBC worldwide case study,” IEEE Transactions on Engineering Management, 1(59), pp. 20-32, 2010.

S. L. Chee, M. Y. Mong, J. F. Chin, “Milk-run kanban system for raw printed circuit board withdrawal to surface-mounted equipment,” Journal of Industrial Engineering and Management, 5(2), pp. 382-405, 2012.

P. Jonsson, S. A. Mattsson, “Inventory management practices and their implications on perceived planning performance,” Internation Journal of Production Research, 46(7), pp. 1787-1812, 2008.

C. Ladas, “Scrumban: Essays on kanban systems for lean software development,” WA: Modus Cooperandi Press, Seattle, 2008.

T. Al-Hawari, F. Aqlan, “A software application for ekanban based WIP control in the alumunium industry,” International Journal Modeling in Operations Management, 2(2), pp. 119-137, 2012.

M. Majchrzak, L. Stilger, “Experience report: introducing kanban into automotive software project,” e-Informatica Software Engineering Journal, 1(11), pp. 39-57, 2017.

A. Naufal, A. Jaffar, N. Yusoff, N. Hayati, “Development of Kanban System at Local Manufacturing Company in Malaysia – Case Study,” in International Symposium on Robotics and Intelligent Sensors, Sarawak, Malaysia, pp. 1721-1726, 2012.