The Effects of Implementation of Kanban System on Productivity : A Case Study of Auto Parts Company

This paper presents a case study of Kanban system implementation in an auto parts manufacturing company. The control system was implemented on three largest selling parts, namely, Emblem Maruti Suzuki, Emblem S Mark and Emblem VXI. These products go through the process of injection molding, plating, painting, assembly and final inspection. Data suggested specifically high in-process inventory during injection molding stage. To reduce such Work-in-Process (WIP) inventory, Kanban was implemented firstly by deducing the number of Kanban required at every stage of process and then examining its effect on reducing stock levels and lead times. The findings suggest significant reduction in daily production quantity, WIP level and process lead time of all three emblems