Implementing Kanbans within high variety/low volume manufacturing environments

Functional plant layouts are normally adopted in organizations that manufacture large varieties of components in low annual volumes. Attempts to improve the efficiency of these layouts have normally focused on the identification and implication of group technology cells which process a limited range of parts using flow process principles. Cell layouts provide the condition for kanban control procedures to operate, hence the benefits of just‐in‐time can be achieved in batch processing environments. However, in high variety/low volume (HV/LV) environments there is often insufficient commonality between part types to justify the formation of cells. Describes an alternative plant layout procedure (process sequence cell layout) currently being developed that allocates equipment to cells according to their position in the process routes of components. Uses a case study to illustrate how such a layout may be identified for an organization that has a typical high variety/low volume environment. Discusses the problems that need to be overcome if such systems are to be implemented and offers a description of how integrated MRP II/kanban control mechanisms can be used to control production.