Kanban-controlled exponential production lines: analysis and design

Purpose - The purpose of this paper is to study kanban-controlled pull-systems with machines having the exponential reliability model and with buffers finite capacities. Design/methodology/approach - Using Markovian analysis closed formulas are derived for the performance metrics such as customer service level, average inventory level, and throttling of raw part release, for one-machine systems. Then, a recursive procedure is developed to extend the performance evaluation technique to multi-machine systems. Findings - Once system-theoretic properties of the systems under consideration are investigated, the paper reveals methods for evaluating the smallest, i.e. lean, number of kanbans that ensure the desired level of customer service which are developed. Originality/value - Production systems can operate in either push or pull regime. The push-systems have been analyzed extensively for over 50 years, while the pull-systems have been studied to a much lesser extent.