Design ,development &

Optimization of E-Kanban
System based on Kanban
Cards with Bar-coding

Mangesh Joshi
(MT09IND006)
3rd Sem. MTech

1st Project seminar

 Contents
1) Company Information
2) Conventional Kanban System in place
3) Project Scope
4) Completed Work
5) References
 Aim
To design , develop and implement software of E- Kanban
and there by transforming conventional Kanban system into
E-Kanban for tractor assembly plant.

Mahindra & Mahindra Plant

 Plant information

ü32 types of tractors are assembled.

üMixed model assembly lines

üFour plants :- Engine, transmission , VTU and tractor assembly

üInvolved in assembly work only

üPurchases components for all types of tractors and inventory is

maintained in warehouse
 Conventional Kanban System
üKanban literally means “visual card,” “signboard.

üKanban is one of the tools to establish just in time.

üIt can be called as a communication system to establish visual control.

üIt overcomes various issues in stores mgmt

i.e. order placement, inventory mgmt

üFirst implemented in Toyota plant

 How Conventional Kanban System Works

1/4 2/4 3/4 4/4

Stores

1/4
Assembly line

Removed Kanban

Attaching Kanban to received containers

Pigeon Hole Box

Entry to Register Vendor Intimation

Why E-Kanban ?

DData Entry Errors

DDifficult task of managing information
DThe process consumes more time
DCalling procedure and waiting of phone call
DInclusion of additional cost and misunderstandings
Literature Review
Optimization Techniques Available

DGenetic Algorithm
DNeural Networks
DMemetic Algorithm
DRule induction Approach
DFuzzy Logic and List is too long
Calculating No of Kanban Cards
 Calculating the Number of Containers
between Work Centers

UT(1+P)
N=
C
N = Total number of containers between 2 stations
U = Usage rate of downstream operation
T = Average elapsed time for container to make
entire cycle
P = Policy variable indicating efficiency... 0 - 1
C = Capacity (number of parts) of standard container

11
WORK CARRIED OUT
esign and development E - Kanban

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Kanban Card Barcode scanner In house Computer Vendor’s Computer

Options available :-
1) Bar-coding
2) RFID
 CardID Card Qty. Name
Email ID

Lead Time Vendor Code

Card_Details
Vendor Details

Buyer Name
Contact Details
Part No
Card No
Part Details

Part Name
ER- Diagram
Card Master Table

Card_ID Ven_code Part_no Card_No Card_Qty Lead_Time Buyer

Card 001 DA007 "000031326B12 1 240 1 S P Deshpande

Card 002 DA027 "005553825R2 0 1000 2 R S Joshi

Card 003 DA027 "005553825R2 2 1000 2 R S Joshi

Card 004 DA027 "005555715R1 0 1000 2 R S Joshi

Card 005 DA027 "005555715R1 2 1000 2 R S Joshi

Card 006 DA027 "000031189B12 0 600 1 P S Kulkarni

Card 007 DA027 "000031189B12 1 600 1 P S Kulkarni

Card 008 DA027 "000031241B12 0 6000 1 P S Kulkarni

Card 009 DA027 "000031241B12 1 6000 1 P S Kulkarni

Card 010 DA071A "000032712B12 0 300 1 R S Kalakota

Card 011 DA071A "000032712B12 1 300 1 R S Kalakota

Vendor email Table

Vendor Code Email_add Cont_Person

DA007 xyznachine@abcfirm.com Mr. sunil

DA022 abmachinary@yahoo.com Mr. Joshi

DA027 asdfd@gmail.com Mr. Patil

DA071A unil@rediffmail.com Mr.Sunil

DA072 nagpur@omlogistics.co.in;nagpur_mis@o Mr. Shankar

mlogistics.co.in

DA100 awonauto1@rediffmail.com;awonauto1@ Sanjay Jawa , Ravi Barapatre

rediffmail.com

DB013 option_sunil@rediffmail.com;option_pras Mr.Sunil

hant@rediffmail.com

DB016 adg_123@yahoo.com Mr Dasgupta

Part Details Master Table
Material Number Material Description

"000000774XPNBP PTO SHIFTER ASSY - NBP

"000012146P04 Bearing 6309 C3

"000012190P04 Bolt

"000012353p04 CIRCLIP EXTERNAL-TRANS. DRIVING SHA

"000012506P04 BOLT HEX HD M12X30 GR 10.9

"000016632P04 OIL SEAL-TRANS.DRIVE SHAFT REAR 30x40x7

"000017244R1 ROLL PIN

"000020303E05 BOLT M12 X 1.75 X 55 HEX.

"000021433R1 O-RING DIFF LOCK --BIG

"000029547D SPRING GEAR SHIFTER LEVER

"000030902B11 INTERLOCK PIN

 Barcode Samples

Code 128 type Barcode Old New

Project Scope
• Material receipt without call

• Editing sent data

• Generating various reports

• Sending mails to transporter, vendors etc

• Optimization of Kanban Card Module

• Alterations will be made based on Mahindra requirements

For journal papers: References
[1] M. Rabbani *, J. Layegh, R. Mohammad Ebrahim :- Determination of number of kanbans in a
supply chain system via Memetic algorithm

[2] F.T.S. Chan (1999) Effect of Kanban Size on JIT manufacturing System. Department of industrial
and manufacturing system engineering

[3] George Liberopoulos*, Stelios Koukoumialos :- Tradeoffs between base stock levels, numbers of
Kanban, and planned supply lead times in production/inventory systems with advance demand
information Department of Mechanical and Industrial Engineering, University of Thessaly, Volos,
Greece

[4] NA S. MARKHAM*, RICHARD G. MATHIEU2 and BARRY A. WRAY:- A RULE INDUCTION

APPROACH FOR DETERMINING THE NUMBER OF KANBANS IN A JUST-IN-TIME PRODUCTION
SYSTEM

For books:

[4] M.G. Koregaonkar(1992) , “Just-In-Time Manufacturing ” MacMillan India Ltd, First Edition
Thank you .!!!