Module-based modeling and analysis of a manufacturing system adopting a dual-card kanban system with a delivery cycle

A systematic procedure for module-based modeling is designed and proposed to simulate of any multistage manufacturing flow type system adopting a dual-card kanban system with a delivery cycle. First, a functional analysis was performed to present kanban flows in exactly the same fashion in a simulation model as they actually appear in a real manufacturing system. One shipping area module, the required number of parts store modules, and one supplier center module were used to develop a designated simulation. Proposed modules have focused dialogs, animation, and modeling functionality. In addition, a procedure to obtain the necessity minimum number of kanbans to achieve no stock-out events is proposed. Then, a numerical example is shown to apply the proposed procedure.