Kanban System Research And Study Based On Small Quantity And Variety Of Modes Of Production

Nowadays,a small quantity and variety of modes of production is increasingly in the electronics factory.Therefore,how to react to more flexible material lot sizes and more frequent product changeovers together with more tough product delivery requirement,proper material management made the following challenges to meet the demands from customers and markets especially in the prospects of material management.Lean manufacturing mode was adopted by Nanjing Siemens Numeral Control Company.Temporary material stock area was worked as a Kanban.Following problems occurred resulted from the use of Kanban management:(1)Incorrect quantity of material request since it is operated manually by the means of the visual inspection(2)Only one material part number corresponds to one Kanban location,therefore the operator need to walk a lot to obtain the material,which would result in frequent material inventory check.(3)Current material detailed information(Material part number,remaining quantity,).is not accessable(4)SMT Production lines interrupted as a result of lack of the materials,so that ROI sharply decreased since very expensive SMT equipment.More variety volume production model suitable material applied Kanban is a very valuable research to increase the material transparency in the shop floor based on the four problems raised by the company,so that the frequency of inventory check will be decreased.This paper mainly covers the following aspects:(1)Firstly,analyze the problems occurred during Kanban management,point out stock efficiency is so low resulted from production can't be cooperate based on the stock properly.(2)Secondly,the shortage of material check manually is identified upon analyzing process of Kanban.Re-design and elaborate the process of Kanban management.(3)Lastly,design and achieve Kanban managements system,which as designed by C/S structure,interfaced with IIM system and setup center via the approach of Micosoft.Net framework and SQL Server 2008.Currently trial run of the system lasted for half a year.Kanban stock area was established and located close to each SMT line.Material preparation was triggered by the material issued by operator of SMT line,so that reduction of material-related line stops to large degree.Moreover,material inventory was counted once half year changed from once per month by the means of Unique ID.The reduction in downtime resulted in cost saving of around 650 thousands RMB.