Implementation of hybrid Kanban-CONWIP system: a case study

Leonardo, Dênis Gustavo; Sereno, Bruno; Silva, Daniel Sant Anna da; Sampaio, Mauro; Massote, Alexandre Augusto; Simões, Jairo Celso

doi:10.1108/jmtm-03-2016-0043

Cited by 27 publications

(7 citation statements)

References 19 publications

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“…This study discussed the lean methods’ contribution to the PI of large auto component manufacturers in India. The extant literature has focused on measuring effectiveness through improvement in individual key performance indicators, such as cycle time, process lead-time and work-in-process inventory, among others (Leonardo et al, 2017). This approach is deemed effective if done at the firm or process level.…”

Section: Discussionmentioning

confidence: 99%

Assessing the moderating role of the extent of implementation of lean methods in predicting productivity improvement

Singla¹,

Sharma²

2023

RAUSP

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Purpose The study aims to explore the argument of implementing the lean method to part or whole of an operation by examining the moderating impact of varying levels of the extent of implementation of four different lean methods, along with their functionalities, in predicting productivity improvement (PI). Design/methodology/approach As the focus of understanding the efficacy of lean principles is shifting from process to industry level, this study tried to generalize the approach by gathering data from 132 large Indian auto component manufacturers. This involves an assessing/monitoring approach rather than measurement. Findings Results highlighted the interdependence or individuality of the extent of implementation of lean methods and their functionalities. Findings revealed a significant moderating effect in improving productivity to a greater extent of 50%. Research limitations/implications Adopting an assessment approach to a measurement study provides a noteworthy contribution to bridging theory and practical consequences. The findings can be appropriately extrapolated to medium and small enterprises forming a critical connection in the entire automobile manufacturing ecosystem. Practical implications The study showed that even if a lean method is applied to a certain extent of operations the chances of PI are significant. This is important for decision makers as they confront problems of optimum resource allocation. Social implications PI, reduced cost and generalization of results would enable the auto component industry to become more competitive. Originality/value The examination of the moderation effect of a lean principle implementation extent, along with that of its functionalities to predict the improvement in productivity from its existing level, is a major outcome of this study.

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Section: Discussionmentioning

confidence: 99%

Assessing the moderating role of the extent of implementation of lean methods in predicting productivity improvement

Singla¹,

Sharma²

2023

RAUSP

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“…Non-repetitive production environments have high product variation in which pull can be accomplished by using a hybrid pull PCS (e.g. CONWIP) containing some push characteristics (Leonardo et al , 2017). All Kanban types can be used in low product variation conditions.…”

Section: Design Of Pull Production Control Systems With Ad Principlesmentioning

confidence: 99%

“…Generally, high demand variability necessitates generic pull PCS. Unlike Kanban, generic CONWIP and POLCA systems are not dedicated to a specific product and can operate in both high product variation and high demand variability environments (Durmusoglu and Satoglu, 2011; Kabadurmus, 2009; Leonardo et al , 2017; Suri, 2018). “External setup times” are discussed in two categories that are long and short external setup times.…”

Section: Design Of Pull Production Control Systems With Ad Principlesmentioning

confidence: 99%

Design of pull production control systems using axiomatic design principles

Kabadurmuş

Durmuşoğlu

2019

JMTM

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Purpose The purpose of this paper is to contribute to the lean manufacturing literature by providing a roadmap for pull production control system (PCS) implementation. Design/methodology/approach Axiomatic Design (AD) methodology is used to develop the proposed pull PCS transformation roadmap. Findings The proposed design methodology is validated in a real-life manufacturing system. The results show that the proposed methodology significantly reduces the design efforts. The methodology effectively helps to choose the most appropriate pull PCS and determine its operational settings with respect to the manufacturing system characteristics. Research limitations/implications This study presents only one case study to test the proposed methodology. In future studies, the validity of the proposed method can be further generalized in different manufacturing sectors by real-life implementations. Practical implications In many real-life lean production projects, companies do not know where to start or how to proceed, which leads to repetitive design efforts and inefficient designs. The developed roadmap of this study minimizes incorrect or imperfect design trials and increases the success of pull production transformation projects. Originality/value The implementation of pull PCS requires extensive design knowledge and expertise. Therefore, many real-life applications fail due to costly and time-consuming trial-and-error-based design efforts. In the literature, there is no comprehensive guideline or roadmap for pull PCS implementation. To address this issue, this study provides a novel holistic roadmap to transform an existing push PCS to pull. The proposed methodology uses AD principles and combines fragmentary studies of the pull production literature.

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“…Hoose et al (2016) implemented a CONWIP system in an agricultural machine industry, observing a reducti on of the material in process and an increase in producti vity. Leonardo et al (2017) implemented the CONWIP system in a factory of electro-mechanical components, reducing cycle ti me and increasing producti on volume. Dallasega and Rauch (2017) have used the CONWIP system principle to synchronize demand and supply in manufacturing leading to the formati on of sustainable supply chains in on-demand project companies.…”

Section: Pulled Pushed and Hybrid Production Schedulingmentioning

confidence: 99%

Performance evaluation of pulled, pushed and hybrid production through simulation: a case study

Pinheiro

Cleto

Zattar

et al. 2019

BJO&PM

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Goal: This work aims to compare performance indicators of the pulled, pushed and hybrid production schedule, with those of a specific production environment of the printing industry, using computational simulation. Design / Methodology / Approach: Through a case study, it was possible to create a conceptual model, from which a computational model that was verified and validated as representative of the real productive system was developed. There are generated fictional models of the production environments to compare cycle time, work in process and attendance to the demand, varying the quantity of orders confirmed by the final clients. Results: The CONWIP (Constant Work in Process) system presented very high cycle times and failure to meeting the demand, although it was kept in the format of the work in process. The actual real system and the pushed system obtained the worst performances regarding the work in process, besides presenting failures to meeting the demand and very high cycle times. The pulled system obtained the best performance to meet the demand, and cycle times adequate to the production requirement and moderate work in process. Limitations of the investigation: The application of the methodology was limited to the study of a single productive system of a print industry and cannot be extended to the entire sector. Practical implications: This work presents a practical application of computer simulation tools applied to Production Planning and Controls which may be replicated by other organizations or educational institutions for system performance analysis in different scenarios. Originality / Value: The original contribution of this work is the application of computational simulation for a production system in a print industry without interference in a real system.

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Implementation of hybrid Kanban-CONWIP system: a case study

Cited by 27 publications

References 19 publications

Assessing the moderating role of the extent of implementation of lean methods in predicting productivity improvement

Assessing the moderating role of the extent of implementation of lean methods in predicting productivity improvement

Design of pull production control systems using axiomatic design principles

Performance evaluation of pulled, pushed and hybrid production through simulation: a case study

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