Abstract: Lean manufacturing is a production philosophy made
popular by Toyota Motor Corporation (TMC). It is globally known as
the Toyota Production System (TPS) and has the ultimate aim of
reducing cost by thoroughly eliminating wastes or muda. TPS
embraces the Just-in-time (JIT) manufacturing; achieving cost
reduction through lead time reduction. JIT manufacturing can be
achieved by implementing Pull system in the production.
Furthermore, TPS aims to improve productivity and creating
continuous flow in the production by arranging the machines and
processes in cellular configurations. This is called as Cellular
Manufacturing Systems (CMS). This paper studies on integrating the
CMS with the Pull system to establish a Big Island-Pull system
production for High Mix Low Volume (HMLV) products in an
automotive component industry. The paper will use the build-in JIT
system steps adapted from TMC to create the Pull system production
and also create a shojinka line which, according to takt time, has the
flexibility to adapt to demand changes simply by adding and taking
out manpower. This will lead to optimization in production.
Abstract: This paper presents a model for an unreliable
production line, which is operated according to demand with constant
work-in-process (CONWIP). A simulation model is developed based
on the discrete model and several case problems are analyzed using
the model. The model is utilized to optimize storage space capacities
at intermediate stages and the number of kanbans at the last stage,
which is used to trigger the production at the first stage. Furthermore,
effects of several line parameters on production rate are analyzed
using design of experiments.