Parallel Kanban-ConWIP System for Batch Production in Electronics Assembly

: This paper describes a novel pull system based on value stream mapping (VSM) in an electronics assembly plant. Production in an assembly plant can be characterized as multi-stage, high mix, by batch, unbalanced, and asynchronous. The novelty of the system lies on the two kanban systems working simultaneously: a standard lot size kanban system for high-demand products (high runners) and a variable lot size constant work-in-process (ConWIP) system for low-demand products (low runners). The pull system is verified through computer simulation and discussions with production personnel. Several benefits are achieved, including level scheduling and significant reduction in the work-in-process (WIP) level. Production flows are regulated through a process called pacemaker, which involves varying the standard lot size and the number of ConWIP kanban. The available interval time could be utilized for other non-kanban-driven parts and routine maintenance (5S). Only a moderate decline in the production output is seen, compared with the target, because of the increase in the overall set-up time, along with the small lot size production. &nbsp