An integrated framework for card-based production control systems

Although card-based control systems, such as Kanban and CONWIP, for production processes have been successfully employed, the design discipline does not seem to be clear yet. Therefore, the superiority of one control over the other is controversial. This paper proposes a novel design discipline for card-based control of production processes, by developing the theory of token transaction systems. The theory shows how the three indices represented in Little's law are decided by the structure of a production process with control cards and deployment of work-in-process (WIP). That is, the relation of WIP, cycle time and throughput on specific sub-network of a production process is clarified. We show how Little's law should be used in the design of card-based production control systems. As an application of the theory, we resolve complicated result of comparison between Kanban and CONWIP. In doing so, this theory does not restrict the target of analysis to serial production lines, but any shaped processes can be analyzed.