project seminar 1st

8/8/2019 Project Seminar 1st

1/21

Design ,development &Design ,development &

Optimization of E-KanbanOptimization of E-KanbanSystem based on KanbanSystem based on Kanban

Cards with Bar-codingCards with Bar-coding

Mangesh Joshi

(MT09IND006)3rd Sem. MTech

1st Project seminar


2/21

1) Company Information

2) Conventional Kanban System in place

3) Project Scope4) Completed Work

5) References

Contents


3/21

To design , develop and implement software of E- Kanban

and there by transforming conventional Kanban system into

E-Kanban for tractor assembly plant.

Aim

Mahindra & Mahindra Plant


4/21

Plant information

32 types of tractors are assembled.

Mixed model assembly lines

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

Involved in assembly work only

Purchases components for all types of tractors and inventory is

maintained in warehouse


5/21

Conventional Kanban System

It overcomes various issues in stores mgmt

i.e. order placement, inventory mgmt

Kanban literally means visual card, signboard.

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

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

First implemented in Toyota plant


6/21

How Conventional Kanban System Works

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

Assem

bly

l ine 1/4

Pigeon Hole Box

Removed Kanban

Entry to Register Vendor Intimation

Attaching Kanban to received containers

Stores


7/21

Why E-KanbanWhy E-Kanban ??

DData Entry Errors

DInclusion of additional cost and misunderstandings

DDifficult task of managing information

DThe process consumes more time

DCalling procedure and waiting of phone call


8/21

Literature ReviewLiterature Review


9/21

Optimization Techniques AvailableOptimization Techniques Available

DGenetic Algorithm

DFuzzy Logic and List is too long

DNeural Networks

DMemetic Algorithm

DRule induction Approach


10/21

Calculating No of Kanban CardsCalculating No of Kanban Cards


11/21

11

N = Total number of containers between 2 stationsN = Total number of containers between 2 stationsU = Usage rate of downstream operationU = Usage rate of downstream operation

T = Average elapsed time for container to makeT = Average elapsed time for container to make

entire cycleentire cycle

P = Policy variable indicating efficiency... 0 - 1P = Policy variable indicating efficiency... 0 - 1C = Capacity (number of parts) of standard containerC = Capacity (number of parts) of standard container

UT(1+P)N=

C

Calculating the Number of ContainersCalculating the Number of Containers

between Work Centersbetween Work Centers


12/21

WORK CARRIED OUTWORK CARRIED OUT


13/21

||||||||||||||||||||||||||

Kanban Card Barcode scanner Inhouse Computer Vendors Computer

-ign and development E Kanba-ign and development E Kanba

Options availableOptions available :-:-1) Bar-coding

2) RFID


14/21

ER- DiagramER- Diagram

Card_Details

Part Details

Vendor Details

CardID

Contact Details

Name

Email ID

Part Name

Part No

Vendor Code

Buyer Name

ead Time

Card Qty.

Card No

Card Master Table


15/21

Card Master Table

Card_IDCard_ID Ven_codeVen_code Part_noPart_no Card_NoCard_No Card_QtyCard_Qty Lead_TimeLead_Time BuyerBuyer

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 010 DA071A "000032712B12 0 300 1 R S Kalakota

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

Vendor email Table


16/21

Vendor email Table

Vendor Code Email_add Cont_Person

DA007 [email protected] Mr. sunil

DA022 [email protected] Mr. Joshi

DA027 [email protected] Mr. Patil

DA071A [email protected] Mr.Sunil

DA072 [email protected];[email protected]

Mr. Shankar

DA100 [email protected];awonauto1@

rediffmail.com

Sanjay Jawa , Ravi Barapatre

DB013 [email protected];[email protected]

Mr.Sunil

DB016 [email protected] Mr Dasgupta


17/21

Part Details Master Table

Material NumberMaterial Number Material DescriptionMaterial 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


18/21

Barcode SamplesBarcode Samples

Code 128 type Barcode OldOld NewNew


19/21

Project ScopeProject 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


20/21

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

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

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

[4] NA S. MARKHAM*, RICHARD G. MATHIEU2 and BARRY A. WRAY:- A RULE INDUCTIONAPPROACH FOR DETERMINING THE NUMBER OF KANBANS IN A JUST-IN-TIME PRODUCTIONSYSTEM

For books:

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


21/21

Thank you .!!!Thank you .!!!

project seminar 1st

Documents