Impact analysis of flow variability in sizing kanbans

Abstract

The aim of this paper is to analyze the effects of variability flow, advocated by Factory Physics, in sizing Kanban production systems. The variability of flow presupposes that the variability of activities performed by a process is dissipated throughout the productive flow system, causing variations in the lead time, the work-in-process levels and the equipment availability, among others. To conduct the research, we created a didactic model of discrete event computer simulation. The proposed model aims to present the possible impacts caused by the variability flow in a production system regarding the sizing of the number of Kanbans cards, by using the results supplied by two different investigated scenarios. The main results of the research allow concluding that, by comparing the two scenarios developed in the model, the presence of variability in the production system caused an average increase of 32% in the number of Kanban cards (p=0,000). This implies that, in real productive systems, the study of Kanban sizing should consider the variability of individual operations, a fact often relegated as an assumption in the formulation from classical literature on the definition of the number of Kanbans, thus providing opportunities for the development of future research.

Keywords

• Kanban. Variabilidade de Fluxo. Modelagem. Simulação Computacional. Factory Physics.