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Design ,development &Design ,development &
Optimization of E-KanbanOptimization of E-KanbanSystem based on KanbanSystem based on Kanban
Cards with Bar-codingCards with Bar-coding
Mangesh Joshi
(MT09IND006)3rd Sem. MTech
1st Project seminar
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1) Company Information
2) Conventional Kanban System in place
3) Project Scope4) Completed Work
5) References
Contents
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To design , develop and implement software of E- Kanban
and there by transforming conventional Kanban system into
E-Kanban for tractor assembly plant.
Aim
Mahindra & Mahindra Plant
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Plant information
32 types of tractors are assembled.
Mixed model assembly lines
Four plants :- Engine, transmission , VTU and tractor assembly
Involved in assembly work only
Purchases components for all types of tractors and inventory is
maintained in warehouse
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Conventional Kanban System
It overcomes various issues in stores mgmt
i.e. order placement, inventory mgmt
Kanban literally means visual card, signboard.
Kanban is one of the tools to establish just in time.
It can be called as a communication system to establish visual control.
First implemented in Toyota plant
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How Conventional Kanban System Works
1/4 2/4 3/4 4/4
Assem
bly
l ine 1/4
Pigeon Hole Box
Removed Kanban
Entry to Register Vendor Intimation
Attaching Kanban to received containers
Stores
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Why E-KanbanWhy E-Kanban ??
DData Entry Errors
DInclusion of additional cost and misunderstandings
DDifficult task of managing information
DThe process consumes more time
DCalling procedure and waiting of phone call
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Literature ReviewLiterature Review
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Optimization Techniques AvailableOptimization Techniques Available
DGenetic Algorithm
DFuzzy Logic and List is too long
DNeural Networks
DMemetic Algorithm
DRule induction Approach
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Calculating No of Kanban CardsCalculating No of Kanban Cards
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N = Total number of containers between 2 stationsN = Total number of containers between 2 stationsU = Usage rate of downstream operationU = Usage rate of downstream operation
T = Average elapsed time for container to makeT = Average elapsed time for container to make
entire cycleentire cycle
P = Policy variable indicating efficiency... 0 - 1P = Policy variable indicating efficiency... 0 - 1C = Capacity (number of parts) of standard containerC = Capacity (number of parts) of standard container
UT(1+P)N=
C
Calculating the Number of ContainersCalculating the Number of Containers
between Work Centersbetween Work Centers
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WORK CARRIED OUTWORK CARRIED OUT
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Kanban Card Barcode scanner Inhouse Computer Vendors Computer
-ign and development E Kanba-ign and development E Kanba
Options availableOptions available :-:-1) Bar-coding
2) RFID
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ER- DiagramER- Diagram
Card_Details
Part Details
Vendor Details
CardID
Contact Details
Name
Email ID
Part Name
Part No
Vendor Code
Buyer Name
ead Time
Card Qty.
Card No
Card Master Table
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Card Master Table
Card_IDCard_ID Ven_codeVen_code Part_noPart_no Card_NoCard_No Card_QtyCard_Qty Lead_TimeLead_Time BuyerBuyer
Card 001 DA007 "000031326B12 1 240 1 S P Deshpande
Card 002 DA027 "005553825R2 0 1000 2 R S Joshi
Card 003 DA027 "005553825R2 2 1000 2 R S Joshi
Card 004 DA027 "005555715R1 0 1000 2 R S Joshi
Card 005 DA027 "005555715R1 2 1000 2 R S Joshi
Card 006 DA027 "000031189B12 0 600 1 P S Kulkarni
Card 007 DA027 "000031189B12 1 600 1 P S Kulkarni
Card 008 DA027 "000031241B12 0 6000 1 P S Kulkarni
Card 009 DA027 "000031241B12 1 6000 1 P S Kulkarni
Card 010 DA071A "000032712B12 0 300 1 R S Kalakota
Card 011 DA071A "000032712B12 1 300 1 R S Kalakota
Vendor email Table
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Vendor email Table
Vendor Code Email_add Cont_Person
DA007 [email protected] Mr. sunil
DA022 [email protected] Mr. Joshi
DA027 [email protected] Mr. Patil
DA071A [email protected] Mr.Sunil
DA072 [email protected];[email protected]
Mr. Shankar
DA100 [email protected];awonauto1@
rediffmail.com
Sanjay Jawa , Ravi Barapatre
DB013 [email protected];[email protected]
Mr.Sunil
DB016 [email protected] Mr Dasgupta
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Part Details Master Table
Material NumberMaterial Number Material DescriptionMaterial Description
"000000774XPNBP PTO SHIFTER ASSY - NBP
"000012146P04 Bearing 6309 C3
"000012190P04 Bolt
"000012353p04 CIRCLIP EXTERNAL-TRANS. DRIVING SHA
"000012506P04 BOLT HEX HD M12X30 GR 10.9
"000016632P04 OIL SEAL-TRANS.DRIVE SHAFT REAR 30x40x7
"000017244R1 ROLL PIN
"000020303E05 BOLT M12 X 1.75 X 55 HEX.
"000021433R1 O-RING DIFF LOCK --BIG
"000029547D SPRING GEAR SHIFTER LEVER
"000030902B11 INTERLOCK PIN
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Barcode SamplesBarcode Samples
Code 128 type Barcode OldOld NewNew
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Project ScopeProject Scope
Material receipt without call
Editing sent data
Generating various reports
Sending mails to transporter, vendors etc
Optimization of Kanban Card Module
Alterations will be made based on Mahindra requirements
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ReferencesReferencesFor journal papers:[1] M. Rabbani *, J. Layegh, R. Mohammad Ebrahim :- Determination of number of kanbans in asupply chain system via Memetic algorithm
[2] F.T.S. Chan (1999) Effect of Kanban Size on JIT manufacturing System. Department of industrialand manufacturing system engineering
[3] George Liberopoulos*, Stelios Koukoumialos :- Tradeoffs between base stock levels, numbers ofKanban, and planned supply lead times in production/inventory systems with advance demandinformation Department of Mechanical and Industrial Engineering, University of Thessaly, Volos,Greece
[4] NA S. MARKHAM*, RICHARD G. MATHIEU2 and BARRY A. WRAY:- A RULE INDUCTIONAPPROACH FOR DETERMINING THE NUMBER OF KANBANS IN A JUST-IN-TIME PRODUCTIONSYSTEM
For books:
[4] M.G. Koregaonkar(1992) , Just-In-Time Manufacturing MacMillan India Ltd, First Edition
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Thank you .!!!Thank you .!!!