Module-based modeling and analysis of just-in-time production adopting dual-card kanban system and Mizusumashi worker

In this study, we design and develop module-based modeling scheme that can conveniently represent a manufacturing system adopting a dual-card kanban system with a delivery cycle. By combining the designed modules, it is possible to express models of various systems comprising multiple parts, production lines, suppliers, and Mizusumashi (fixed-course pick-up). The module-based modeling scheme is useful for understanding the characteristics of just-in-time manufacturing and helping decision makers build simulation models based on the modules. We focus on modularization of the assembly line and the parts carrying Mizusumashi in a JIT manufacturing system. The proposed modules have focused dialogs, animation, and modeling functionality. In addition, a procedure for finding the optimal number of tray containers and kanbans to achieve no stock-out events is proposed based on the simulation model that integrates the kanban system and the Mizusumashi system. Then, the proposed procedure is applied to a numerical example.