Investigating the Kanban size of the material flow in apparel manufacturing process

Abstract

This study seeks to optimise material flow within the apparel manufacturing process by identifying an optimal Kanban size. Work-in-progress (WIP) fluctuations, resulting from various factors such as product type variations, supplier fluctuations, and fluctuating customer demands, pose significant challenges in dynamic manufacturing environments. Managing these fluctuations through the identification of an optimal Kanban size holds promise for improving production processes. A spreadsheet simulation model was devised that employs cost components that include setup time cost, WIP cost, material handling cost, and under-utilisation of resources cost. Through a comparative study, the impact of varying Kanban size on total costs was evaluated. This systematic examination shed light on how modifications in the Kanban size influenced individual cost components within the cost-objective function. The study aims to determine the appropriate bundle size, called Kanban size, to improve material flow efficiency in apparel manufacturing, thus improving operational efficiency and reducing costs. By optimising Kanban size and minimising WIP fluctuations, the study aims to streamline production processes, resulting in shorter lead times, increased productivity, and reduced waste.