Introduction

KanbanSIM™ is a dynamic tool to measure material flow system performance across time for assembly lines.

• It uses WITNESS™ /SIMUL8™ discrete-event simulation language as its simulation engine
• It has flexible Excel© input interface for input and output
• It is a generic model
• It is easily customizable per application.

KanbanSIM can be used to

• Capture variability in delivery of material and inventory levels at assembly stations
• Show the dynamic traffic interactions.
• Predict impact of material handling on system throughput
• Show the effects of material handling equipment scheduling
• Train engineers and supervisors
• Perform quick "what-if" analysis
   

Overview of Modeling Context

• “Call” and “Card” Kanban systems can be simulated and optimized with KanbanSIMTM

• Motivations for user include
    - avoiding line stock-outs
    - reducing work-in-process inventory
    - finding correct quantity and capacity of transport vehicles
    - avoiding congestion among transport vehicles supplying the line
    - keeping within ergonomic lifting guidelines for material handlers

Structure of Model Input Interface

• Interface is an Excel© workbook; separate worksheets answer questions such as:
  1-What are usage points and usage rates (packaging / containerization)?
  2-What delivery routes are used?
  3-What are delivery train schedules?
  4-What is the aisle segment geometry?
  5-What are the loading and unloading delays?
  6-What is the method of replenishment for each material?

• User can modify routes and other data within the Excel© workbook without revising the WITNESS™ /SIMUL8™ model

Input Data Required

• Model-mix production schedules
• Vehicle capacities
• BOM per model and usage locations per part
• Material packaging
• Operation cycle times
• Recharging frequencies
• Time between failures and time to repair
• CAD layout – usage and delivery locations
• Material handling logic
• Aisle capacity
• Reorder points per part

Structure of Simulation Model

• The model is built automatically (no need for WITNESSTM/Simul8TM experience)
• It contains two large arrays of:
  1-“buffers” representing workstations which consume “parts” representing components assembled raw material
  2-“machines” representing stop-points along delivery routes where trains fetch kanban cards and/or deliver needed parts on demand
• User can modify routes and other data within the Excel© workbook without revising the WITNESSTM / Simul8 model

Built-In Kanban Optimization Algorithms

• The simulation model additionally contains a feature which creates kanbans whenever a workstation starves for a part type
• Therefore, when the model is run under kanban-generation mode, the user can effectively optimize the number of kanbans in the system, subject to:
    - Material Handling Equipment capacity
    - Route definition

User Execution of the Model

• The user:
  1-Creates and validates the Excel© workbook
  2-Assigns warm-up period
  3-Assigns run length
  4-Chooses whether or not to observe animation
  5-Starts model execution

Deliverables

• PMC analysis and recommendations of prototype plant
• Analytical Simulation Tool
• Training
• User Manual
• PMC support

Deliverable Performance Metrics

• Total Cost
• Inventory levels – Min, Average, Max
• Throughput in jobs per hour (JPH)
• Material stock outs
• Vehicle utilization
• Trailer / Dolly utilization
• Aisle traffic density/congestion
• Ergonomic metrics
    - Number of lifts per hour
    - Pounds lifted per hour

Benefits of Applying KanbanSIM

• Capital cost savings (vehicles and dollies/trailers, inventory)
• Lean operation based on dynamic, actual production schedules including:
    - Inventory reduction
    - Reduce material handling
• Faster implementation of designs by answering key questions in design phase
• Modeling and optimization for material handling and Kanban System at one-third the cost of using other simulation and optimization tools.
   

KanbanSIM Applications include

• Bodyshop, Trim and Final assembly
    - Over 500 points of material consumption
• Engine component assembly material flow simulation
    - Identify correct number of vehicles subject to ergonomic and packaging constraints
    - Identify packaging impact on system
• External Material Flow Simulation
    - Reduce container fleet size by 18%
    - $2M capital cost savings in shipping system
• Automotive Distribution Center Simulation and Optimization
    - 25% reduction in transportation costs
• Dock-to-dock material flow simulation tool for automotive supplier
   

For more information, please send email to PMC's KanbanSIM team or telephone 313-441-4460 x1180.