Parallel kanban-CONWIP for production system with rework entrance
by Mei Yong Chong; Shaliza Azreen Mustafa; Joshua Prakash; Jeng Feng Chin
International Journal of Manufacturing Research (IJMR), Vol. 8, No. 4, 2013

Abstract: Parallel kanban-constant work in process (WIP) (CONWIP) (PKC) integrates kanban and CONWIP systems to regulate separately production of high- and low-demand items. This paper studies the performance of PKC variants under a production environment that requires the entrance of rework parts. A case study was performed at an electronics assembly plant with a three-stage asynchronous processing. Discrete-event simulations were conducted using an analysis enhanced by multi-factor ANOVA and response surface methodology. The studied performance measures were the total output, average WIP, flow times, and average bottleneck utilisation. A harmonising effect of the high- and low-demand items was observed when item composition was maintained at a certain ratio. The merge rework policy was consistently superior to the original rework policy. The categorisation in loading rule effectively reduced variations in PKC performance. [Received 22 June 2012; Revised 10 October 2012; Accepted 4 March 2013]

Online publication date: Wed, 29-Jan-2014

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