Implementing Kanbans within high variety/low volume manufacturingenvironments

Authors: Stockton, D.J.; Lindley, R.J.

Source: International Journal of Operations & Production Management, Volume 15, Number 7, 1995 , pp. 47-59(13)

Publisher: Emerald Group Publishing Limited

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Abstract:

Functional plant layouts are normally adopted in organizations thatmanufacture large varieties of components in low annual volumes.Attempts to improve the efficiency of these layouts have normallyfocused on the identification and implication of group technology cellswhich process a limited range of parts using flow process principles.Cell layouts provide the condition for kanban control procedures tooperate, hence the benefits of just-in-time can be achieved in batchprocessing environments. However, in high variety/low volume (HV/LV)environments there is often insufficient commonality between part typesto justify the formation of cells. Describes an alternative plant layoutprocedure (process sequence cell layout) currently being developed thatallocates equipment to cells according to their position in the processroutes of components. Uses a case study to illustrate how such a layoutmay be identified for an organization that has a typical highvariety/low volume environment. Discusses the problems that need to beovercome if such systems are to be implemented and offers a descriptionof how integrated MRP II/kanban control mechanisms can be used tocontrol production.

Keywords: Cell Manufacturing; Continuous Improvement; Just-In-Time; Kanban; Materials Management; Process Control

Document Type: Research article

DOI: http://dx.doi.org/10.1108/01443579510090417

Publication date: 1995-07-01