Optimizing milk-run system and IT-based Kanban with artificial intelligence: an empirical study on multi-lines assembly shop floor

Figures & data

Figure 1. Research framework.

Figure 2. Layout of the shop floor.

Figure 3. (a) Kanban cards. (b) Kanban rack.

Figure 4. ITK workflow.

Figure 5. HIS algorithm.

Table 1. Line-Path Incidence matrix.

#PATH	LINE 1	LINE 2	LINE 3	LINE m
# 1	a11	a12	a13	a1m
# 2	a21	a22	a23	a2m
# 3	a31	a32	a32	a3m
# n	an1	an2	an3	anm

Table 2. Case # 1 – Q = 35.

#PATH	LINE 1	LINE 2	LINE 3	LINE 4	LINE 5	LINE 6	LINE 7	LINE 8	LINE 9	LINE 10	LINE 11
# 1	1	1	1	0	0	1	0	0	0	1	1
# 2	1	1	1	0	0	0	1	1	0	1	0
# 3	1	0	1	0	0	1	1	0	0	1	1
# 4	1	0	1	1	0	0	1	1	0	0	1
# 5	1	0	1	0	1	1	1	0	0	1	0
# 6	1	0	0	0	0	1	0	1	1	1	1
# 7	1	1	1	0	0	1	0	0	0	1	1
# 8	0	0	1	0	0	1	1	0	0	1	1
# 9	0	0	1	1	0	0	1	1	0	0	1
# 10	0	0	1	0	1	1	1	0	0	1	0
# 11	1	0	0	0	0	1	0	1	1	1	1
# 12	0	1	1	0	0	1	0	0	0	1	1
# 13	1	1	1	0	0	0	1	1	0	1	0
# 14	1	0	1	0	0	1	1	0	0	1	1
# 15	0	0	1	1	0	0	1	1	0	0	1
# 16	1	0	1	0	1	1	1	0	0	1	0
# 17	1	0	0	0	0	1	0	1	1	1	1
# 18	0	0	0	0	0	1	0	1	1	1	1

Figure 6. Paths #4; #14.

Figure 7. MRS paths.

Table 3. Demand required.

	Line 1	Line 2	Line 3	Line 4	Line 5	Line 6	Line 7	Line 8	Line 9	Line 10	Line 11
Di, dem and	70	54	83	39	29	50	24	76	39	57	43

Table 4. Path times.

Quantity	Q45	Q46	Q47	Q48	Q49	Q50	Q51	Q52	Q53	Q54	Q55
Total time [min]	460	465	461	467	469	463	470	473	475	476	472

Table 5. MRS quantity Q_min = 35.

	Line 1	Line 2	Line 3	Line 4	Line 5	Line 6	Line 7	Line 8	Line 9	Line 10	Line 11
Path 1	8	5	8	0	0	6	0	0	0	4	4
Path 2	8	5	8	0	0	0	3	7	0	4	0
Path 3	8	0	8	0	0	6	3	0	0	6	4
Path 4	8	0	8	5	0	0	3	7	0	0	4
Path 5	8	0	8	0	4	6	3	0	0	6	0
Path 6	8	0	0	0	0	6	0	7	4	6	4
Path 7	4	5	8	0	0	0	3	7	4	0	4
Path 8	0	0	0	5	4	6	0	7	4	5	4
Path 9	0	5	8	4	0	0	3	7	4	0	4
Path 10	0	5	5	0	4	0	0	7	4	6	4
Path 11	8	5	1	0	0	0	0	7	4	6	4
Path 12	0	5	4	5	4	6	0	7	0	0	4
Path 13	0	5	4	5	4	0	0	7	0	6	4
Path 14	0	5	0	5	4	1	3	7	0	6	4
Path 15	6	0	0	5	0	0	3	7	4	6	4
Path 16	0	5	0	5	4	6	0	7	4	0	4
Path 17	0	5	0	5	4	6	3	0	4	4	4
Path 18	0	0	3	5	4	6	3	0	4	6	4
Qi, tot	66	55	73	49	36	55	30	91	40	71	64

Table 6. MRS quantity Qmin = 40.

	Line 1	Line 2	Line 3	Line 4	Line 5	Line 6	Line 7	Line 8	Line 9	Line 10	Line 11
Path 1	8	5	8	0	2	6	0	7	4	0	0
Path 2	8	5	8	2	4	6	0	7	0	0	0
Path 3	8	5	7	0	0	6	3	7	0	0	4
Path 4	8	5	8	0	0	0	0	7	4	4	4
Path 5	0	0	8	5	0	6	0	7	4	6	4
Path 6	8	5	8	5	0	0	0	0	4	6	4
Path 7	0	0	6	0	4	6	3	7	4	6	4
Path 8	5	5	0	5	4	0	0	7	4	6	4
Path 9	0	5	0	5	0	6	3	7	4	6	4
Path 10	8	5	7	5	0	0	0	7	4	0	4
Path 11	8	0	8	0	4	0	0	7	4	5	4
Path 12	0	5	7	0	4	0	3	7	4	6	4
Path 13	7	0	0	5	4	0	3	7	4	6	4
Path 14	0	5	0	5	4	2	3	7	4	6	4
Path 15	0	5	0	5	4	2	3	7	4	6	4
Path 16	0	5	3	5	4	6	3	0	4	6	4
Qi, tot	68	60	78	47	38	46	24	98	56	69	56

Table 7. MRS quantity Qmin = 45.

	Line 1	Line 2	Line 3	Line 4	Line 5	Line 6	Line 7	Line 8	Line 9	Line 10	Line 11
Path 1	8	5	8	0	0	0	3	7	4	6	4
Path 2	8	5	7	0	4	6	0	7	4	0	4
Path 3	8	5	8	0	0	6	3	7	0	4	4
Path 4	8	5	8	0	0	6	3	7	4	0	4
Path 5	8	0	8	5	0	6	3	7	4	0	4
Path 6	0	5	8	5	3	0	3	7	4	6	4
Path 7	8	5	8	0	3	0	0	7	4	6	4
Path 8	8	5	0	5	0	6	0	7	4	6	4
Path 9	8	5	8	5	4	0	0	7	4	0	4
Path 10	0	5	5	5	0	6	3	7	4	6	4
Path 11	0	5	7	5	4	0	3	7	4	6	4
Path 12	8	5	0	5	4	6	0	7	0	6	4
Path 13	6	5	5	4	4	3	3	7	3	5	2
Path 14	1	5	6	4	3	6	1	6	4	6	3
Qi, tot	79	65	86	43	29	51	25	97	47	57	53

Table 8. MRS quantity Qmin = 50.

	Line 1	Line 2	Line 3	Line 4	Line 5	Line 6	Line 7	Line 8	Line 9	Line 10	Line 11
Path 1	8	5	8	5	3	0	0	7	4	6	4
Path 2	8	5	8	0	2	6	0	7	4	6	4
Path 3	7	5	8	0	0	6	3	7	4	6	4
Path 4	8	5	8	5	0	0	3	7	4	6	4
Path 5	8	5	8	5	4	6	3	7	0	0	4
Path 6	8	5	7	0	4	6	3	7	0	6	4
Path 7	8	5	8	5	4	6	3	7	0	0	4
Path 8	8	0	6	5	4	6	0	7	4	6	4
Path 9	0	5	8	5	4	4	3	7	4	6	4
Path 10	8	5	8	5	0	0	3	7	4	6	4
Path 11	0	5	6	5	4	6	3	7	4	6	4
Path 12	0	5	8	3	4	6	3	7	4	6	4
Path 13	0	3	8	5	4	6	3	7	4	6	4
Qi, tot	71	58	99	48	37	58	30	91	40	66	52

Table 9. MRS quantity Qmin = 55.

	Line 1	Line 2	Line 3	Line 4	Line 5	Line 6	Line 7	Line 8	Line 9	Line 10	Line 11
Path 1	8	5	8	0	4	6	3	7	4	6	4
Path 2	8	5	8	0	4	6	3	7	4	6	4
Path 3	8	5	8	5	0	6	3	7	4	5	4
Path 4	8	5	8	5	4	6	0	7	4	4	4
Path 5	8	5	8	0	4	6	3	7	4	6	4
Path 6	8	5	8	5	4	4	0	7	4	6	4
Path 7	8	5	8	5	0	5	3	7	4	6	4
Path 8	8	5	7	5	0	6	3	7	4	6	4
Path 9	8	5	8	0	4	6	3	7	4	6	4
Path 10	7	4	6	5	3	6	3	7	4	6	4
Path 11	8	5	3	5	4	6	3	7	4	6	4
Path 12	8	5	3	4	4	6	3	7	4	6	4
Qi, tot	95	59	83	39	35	69	30	84	48	69	48

Figure 8. LT values.

Figure 9. MHT values.

Figure 10. WiP values.

Figure 11. WS values.

Figure 12. MS values.

Figure 13. A comparison between the mean value of each parameter and the Q_min is shown in Figure 13, which highlights the dependence of LT, MHT, WIP, WS and MS with the quantity shipped by the MRS.