Production System Improvement Through Kanban Application in Labor Intensive Company

Abstract

Delivery performance is essential for a manufacturer to meet customer requirement. The only manufacturer with fast, accurate and on time delivery could survive in global competition as a sports shoe manufacturer with the labor-intensive production process, PT. XYZ faced a problem with massive work in process inventory that impacted low delivery performance. This research aims to support the shoe manufacturer company to reduce work in process inventory by applying Kanban System. The manufacturer company can decrease work in process in the production line and cut the lead time of production. Kanban System can be utilized from receiving material process, production process, until the packaging process. By implementing a kanban system correctly and consistently, the company can control material supply, production material usage, and customer order delivery inaccurate process. With controlled those items, the company could monitor and manage material and process from beginning to end of the process, even to monitor distribution to a customer. The result of analysis proves that by applying kanban system can achieve the specified daily production target without work in process inventory.

Perancangan Sistem Kanban untuk Mengurangi Work In Process di Lantai Produksi

“…Sesuai dengan penelitian [20], [21], dalam penelitiannya sistem kanban dapat menurunkan jumlah WIP dan penumpukan material dalam proses produksi. Pada penelitian yang sama [22], [23], aplikasi sistem kanban dalam proses produksi dapat merubah sistem dorong menjadi sistem tarik dengan kartu kanban yang mampu meningkatkan jumlah produksi perharinya. Dalam penelitian lain sistem kanban dapat mengurangi waste inventory pada proses produksi di PT Dasa Windu Agun [24].…”

Effectiveness of Supply Management Using Kanban System in Hospital Pharmacy Logistics: A Case Study

“…Kanban is a Japanese word which means "visible sign" or card (Surendra et al, 1999). Kanban is defined as a Material Flow Control Mechanism (MFC) and controls the right amount and right time of production of the required product (Triana & Beatrix, 2019). It has been used around the world to mean card for using cards to arrange the delivery and or production of parts, goods, or raw materials (Graves et al, 1995).…”

Exploration of Production Methods Being Used by Clothing Manufacturing Companies in Zimbabwe Towards a Competitive Strategy

“…Iannuzzi (2019) mentioned that Kan ban is a method that is card based used to convey instructions that are supported by the reasoning that nothing will be produced until it is needed to avoid inventory pileup. It reduces waste and improves the production system efficiency by the use of cards that are employed to authorize the production, release material into each production stage and also plan the efficient and effective flow (Triana & Beatrix, 2019). As stated by Dai and Tayur (2017), Kan ban makes a company gain profitability because it insists on customer demand drive production.…”

“…The pull approach minimizes human made interruptions and delays and it enables a smooth production process in which material flow through the entire sequence smoothly follow. Triana and Beatrix (2019) highlights that problem areas are highlighted by measuring lead time and cycle time of full process and process steps. Operators know steps to take as soon as trouble arises and they also know where to report when problems occur.…”