Algorithms for the design of a multi-stage adaptive kanban system

Abstract

The traditional kanban system with a fixed number of cards does not work satisfactorily in an unstable environment. With the adaptive kanban-type pull control mechanism, the number of kanbans is allowed to change with respect to the inventory and backorder level. It is required to set the threshold values at which cards are added or deleted, which is part of the design. Previous studies used local search and meta-heuristic methods to design an adaptive kanban system for a single stage. In a multi-stage system the cards are circulated within the stage and their presence at designated positions signals to the neighbouring stages details concerning the inventory. In this work, a model of a multi-stage system adapted from a traditional and adaptive kanban system is developed. A genetic and simulated annealing algorithm based search is employed to set the parameters of the system. The results are compared with a traditional kanban system and signs of improvement are found. The numerical results also indicate that the use of a simulated annealing algorithm produces a better solution.

Keywords:

• advanced manufacturing processes
• advanced manufacturing technology
• adaptive control
• JIT
• kanban
• lean manufacturing