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Full Description
Many shops have simplified their production control by using card-based systems such as kanban and Constant Work-in-Process (ConWIP). Although these systems provide a simple and highly effective visual approach for controlling manufacturing and service operations, all too many shops struggle with failed implementations or achieve results that fall below expectations. These outcomes can be attributed to a poor fit between the actual control problem and the solution applied.
This book takes a different approach to most other books on the subject—as it starts with an introduction to the control problem, instead of the control solution. Card-Based Control Systems for a Lean Work Design outlines how the problems encountered in typical manufacturing shops and service providers can be characterized, which allows for improved problem diagnosis.
The first four chapters of the book lay the foundations for problem diagnosis. The next three chapters then discuss, in sequence, each of the three "traditional" card-based control systems: kanban, ConWIP, and Paired-cell Overlapping Loops of Cards with Authorization (POLCA). The book explains how each of these card-based control systems works and identifies the specific type of control problem to which each system applies.
The next two chapters focus on Control of Balance by Card-Based Navigation (COBACABANA), a system developed for high-variety shops producing made-to-order, customized products. This is the first book to discuss this novel approach, which includes the use of cards to estimate due dates or delivery time allowances.
The book closes with a framework that provides guidance on which system to apply. This framework contrasts the control problem with the control solution. The potential of combining card-based systems is also discussed to create a nested solution.
Contents
Basic ConceptsHighlightsWhat Is a Production/Service System?What Is a Business Operation/Process?What Does a Card-Based Control System Actually Control?Why Use a Card-Based Control System Rather than the Latest Technology?Summary: What Card-Based Control Systems Do (And What They Do Not Do) 20Highlights Revisited Basic Principles Underpinning a Card-Based Control SystemHighlightsInput/Output ControlVisualizing the Stability of the Shop Floor/Station: The Throughput DiagramSummary: Input/Output Control Underpinning Card-Based ControlHighlights Revisited Simplified Scheduling through Pool Sequencing and a Shop Floor Dispatching RuleHighlightsSome Rules for Priority Dispatching on the Shop FloorVisualizing On-Time Performance: The Order Progress DiagramSummary: Simplified Scheduling through Priority DispatchingHighlights Revisited How to Diagnose a Control Problem?HighlightsCriterion 1: Make/Produce/Assemble/Build/Serve, etc. To-Stock or To-Order Criterion 2: The Customer Penetration (Inventory/Order Separation) PointCriterion 3: Routing CharacteristicsCriterion 4: Variability and Uncertainty in Resource RequirementsSummary: Diagnosing the Control ProblemHighlights Revisited The Inventory Control Problem: Kanban SystemsHighlightsKanban for the Internal Supply Chain: The Six Rules of Kanban SystemsWork-in-Process Kanban vs. Production KanbanKanban for Shop Floor ControlApplicability of Kanban SystemsSummary: Kanban SystemsHighlights Revisited The Low Variability Order Control Problem: ConWIPHighlightsConWIP: How Does It Work?The Applicability of ConWIPSummary: ConWIPHighlights Revisited Inventory Control Plus Material Requirements Planning for the Order Control Problem: POLCAHighlightsPaired-Cell Overlapping Loops of Cards with Authorization (POLCA): How Does It Work?Applicability of POLCASummary: POLCAHighlights Revisited How to Solve the High Variety Order Control Problem: COBACABANAHighlightsControl of Balance by Card-Based Navigation (COBACABANA)COBACABANA: How Does It Work?Balancing Workloads: The Main Order Release Function of COBACABANACOBACABANA Recognizes the Difference between Direct and Indirect WorkSimplifying the Need for Processing Time EstimationsCOBACABANA and High Processing Time Variability: Starvation AvoidancePremature Station Idleness and Order ReleaseSummary: COBACABANAHighlights Revisited COBACABANA's Card-Based System for Delivery Time Estimation HighlightsCard-Based Delivery Time Estimation: How Does It Work?COBACABANA as a Comprehensive SystemUsing the Salesperson's Display for Output ControlSummary: COBACABANA's Delivery Date Estimation ProcedureHighlights Revisited Summary: Framework of ApplicabilityHighlightsLoop Structure and Its Implications for the Application of Card-Based SystemsCard Properties and Their Implications for the Application of Card-Based SystemsThe Need for IT Support and Its Implications for the Application of Card-Based SystemsFinal Considerations: Nested Card-Based Control SystemsImplementation Information
