Title: Performance study of parallel kanban-base stock for a high-mix multi-stage production system with the entrance of rework

Authors: Shaliza Azreen Mustafa; Joshua Prakash; Chong Mei Yong; Chin Jeng Feng

Addresses: School of Mechanical Engineering, Universiti Sains Malaysia (USM), Engineering Campus, 14300 Nibong Tebal, Penang, Malaysia; School of Manufacturing Engineering, Universiti Malaysia Perlis, Pauh Putra Campus, 02600, Arau, Perlis, Malaysia ' Faculty of Engineering and Green Technology, Universiti Tunku Abdul Rahman, Perak Campus, Jalan Universiti, Bandar Barat, 31900 Kampar, Perak, Malaysia ' School of Mechanical Engineering, Universiti Sains Malaysia (USM), Engineering Campus, 14300 Nibong Tebal, Penang, Malaysia ' School of Mechanical Engineering, Universiti Sains Malaysia (USM), Engineering Campus, 14300 Nibong Tebal, Penang, Malaysia

Abstract: The present study evaluates the performance of parallel kanban-base stock (PKB) system to regulate the production of high-mix items in a multi-stage shared-machine facility with the entrance of rework. The high-runner products are handled using a kanban system and low-runner products using a base stock system. The PKB systems were differentiated in terms of the model driver, loading rule, and rework entrance policy. The performance measures adopted the total output, average work-in-process, flow times and average machine utilisations. Discrete-event simulations were conducted with an analysis constituted of multi-factor ANOVA and response surface methodology. From the analysis, there is a specific R(LR) value that gives desired performance, and at the same time, its dependency is solely on accuracy of regression equation. Between rework policies, predominantly merge rework entrance policy yields more desirable results as observed within performance measures, compared to original rework entrance policy.

Keywords: lean production; kanban; parallel base stock; mixed pull systems; rework; high-mix production; multi-stage production; simulation; response surface methodology; RSM; total output; WIP; work-in-process; flow times; machine utilisation; discrete-event simulation; ANOVA.

DOI: 10.1504/IJAOM.2014.064874

International Journal of Advanced Operations Management, 2014 Vol.6 No.3, pp.227 - 253

Received: 29 Jan 2013
Accepted: 08 Jan 2014
Published online: 30 Sep 2014 *

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