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Kanban System for Industry 4.0 Environment

Article in International Journal of Engineering and Technology · October 2018

DOI: 10.14419/ijet.v7i4.16.21780

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 International Journal of Engineering & Technology, 7(4.16) (2018) 60-65

International Journal of Engineering & Technology

Website: www.sciencepubco.com/index.php/IJET

Research paper

Kanban System for Industry 4.0 Environment

Laila El Abbadi 1*, Said El Manti1, Mariam Houti1 and Samah Elrhanimi1
1
National School of Applied Sciences of Kenitra, Ibn Tofail University, PoBox 242, university avenue, Kenitra, Morocco.
*Corresponding author E-mail:laila.elabbadi@uit.ac.ma

Abstract

Kanban is a lean tool for pull production system that controls the flow of material between workstations by using kanban signal. During
years, this kanban signal is taking use of new technologies given by industrial revolutions. The latest one described the industry 4.0 as
the industry of the future based on cyber-physical systems. In this context, this paper discusses the functioning of new kanban system for
industry 4.0 environment, called kanban 4.0. At first, the current functioning of kanban system was analyzed and object interactions were
demonstrated. Afterwards, two potential functioning of kanban system within industry 4.0 environment were presented, focusing on po-
tential object roles and interactions, in case when the product is smart and the other one considering the smart bin/container. The pro-
posed functioning was discussed with industrial experts and can constitute a basis for further researches.

Keywords: Industry 4.0; kanban; kanban 4.0; lean manufacturing; lean production system.

and highest quality by a specific organization of production and

1. Introduction handling processes [1] by eliminating all wastes in the processes
[17, 18].
The lean production system was created after the Second World Based on a pull approach, the need to program the operations in
War at Toyota Company [1] to organize the production systems case of request is not more relevant anymore. Decisions according
and its components in order to reach the shortest lead time with order of production are taken by operator, using an information
minimum cost and highest quality [1]. Among lean production system that connects the operations through the process [19]. The
tools the kanban system [2] that manages the flow of materials kanban system is part of this production information system [20].
from one workstation to another [3, 4]. It means that each custom-
er workstation communicates directly its need to its supplier 2.2. Kanban System
workstation [5] using material kanban cards. While the infor-
mation technology is evolved and informatics were integrated in Kanban is a tool for pull production system [2] that manages the
the manufacturing system, a digital kanban signal, called e-kanban, movement of materials from one operation to another [3], by using
replaced kanban cards [6] and works around some kanban card a kanban card or a digital kanban signal. Each kanban signal is a
limitations [7, 8] such as card lost [9] and difficulties to be manufacturing order for a specific product [9, 21, 22]. It triggers
adapted to fluctuating demand [10]. the performing of a work only when it is necessary [22], thereby,
In 2011, the industry of the future has been presented at the Han- It allows maintaining a given level of the flow of the material in
nover Fair under the name of industry 4.0 [11]. The German gov- the process [4]. Also, it is used to communicate effectively with
ernment initiated this project of smart factories and encouraged internal and external operations on issues such as production
the industry to accelerate the procedure in using this new revolu- schedules, delivery time and stock information [5].
tion [12] which is based on a cyber-physical system [13] that uses
emerging technologies such as wireless sensor [14] and implies 2.2.1. Traditional Kanban System
the inter-connection and inter-communication between objects.
The production system will be then transformed to a cyber- The traditional kanban system is based on kanban cards. Each card
physical production system [15] and the manufacturing/ organiza- is specific to a determined part of production process [9, 21]. It
tion tools must be adapted to the industry 4.0 environment [16] contains all the information and details required for each process
including kanban system. step [9, 23].
The aims of this paper is to analysis the current functioning of The kanban card system remains simple to implement with low
Kanban system and describe its potential functioning within the cost [22], hence there is a continuous flow control of production
industry 4.0 environment focusing on object interactions and roles. and stocks [9]. Although, it has some limitations due to the unpro-
ductive work caused by the manipulation of cards [24]. The
movement of kanban cards always has some irregularities, since
2. Kanban System they are not moved at the exact time as the consumption of mate-
rials [24], while the pace of manufacturing operations increases
2.1. Lean Production System and the size of the production batch, the number of card move-
ments increases too; as result, cards are lost or misplaced some-
The lean production system was created in 1950s at Toyota Com- times, causing immediate problems in just-in-time production [9].
pany [1]. It aims to reach shortest lead time with minimum cost Decreases or increases in demand for sudden products can also
Copyright © 2018 Authors. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted
use, distribution, and reproduction in any medium, provided the original work is properly cited.
International Journal of Engineering & Technology 61

cause problems for a traditional kanban system, because it requires Since it publication, the interest is remarkable of industrials and
adjusting the number of cards used as well as updating the infor- researches worldwide. However, until today, there is no agreed
mation contained in kanban cards [10]. definition of industry 4.0 [27]. It can be considered as the fourth
In addition, kanban card system is not suitable for all enterprises, industrial revolution applying the principles of cyber-physical
especially those with fluctuating demand, poor quality production systems, internet and future oriented technologies and smart sys-
processes, or having a relatively wide variety of products [22]. tems with enhanced human-machine interaction paradigms [28]. A
cyber-physical system combines the physical world with the cyber
2.2.2. Electronic Kanban System or E-Kanban System world by embedded computer controlled feedback loops [13]. The
production system is then transformed to a cyber-physical produc-
To get around the traditional kanban limits, the most optimal solu- tion system [15] with radical changes in the execution of opera-
tion is the use of the electronic kanban system, based on a digital tions [28]. In contrast to conventional forecast based on produc-
signal, which offers many advantages over the kanban card system tion planning, industry 4.0 enables real-time planning of produc-
[8]. tion, along with dynamic self-optimization [28].
The electronic kanban system (also referred as e-kanban) is a sig-
naling system that uses a mixture of technology, such as barcodes, 3.3. Industry 4.0 for Lean Production System
RFID (Radio Frequency Identification) and electronic messages
[6], to trigger the movement of materials within a manufacturing Researchers agreed that the industry 4.0 can be integrated in lean
or production facility [6]. By using these technologies, the kanban production system and beyond that improve lean production by
system can be more reliable [7], with few errors in card manage- increased integration of information and communication technolo-
ment and decision making [7]. This kanban system can be inte- gies (ICT) [29]. Hence, the new manufacturing environment will
grated into enterprise resource planning systems (ERP) [10], be characterized by the following four elements:
which contain all the company's information in a centralized data-
base. 3.3.1 Augmented Operator
E-kanban acts as a "command panel", which allows real-time visi-
bility of demand signals and gives an overview of the status of The industry 4.0 environment will enable new types of interac-
each workstation in the system [21]. All transaction-related infor- tions between operators and machines [30] also new mission /role
mation is automatically collected and analyzed at different stages to be accomplished by operator. In fact, the operator will be a
of the manufacturing process to control and make decisions in decisions maker and a problem solver [27] as well as in charge of
relation to the size of production batches, hence the definition of supervision and control of ongoing activities [27, 29] within a
the passage time of the products [7, 21]. reduced time of reaction [29, 31] by using innovative technology.
The e-kanban supports implementing a Pull production system in Therefore, he will be transformed to an augmented operator who
a manufacturing environment where the traditional kanban system is capable to interact with intangible assets and digital contents in
would face difficulties [7]. It can be used with a production flow highly interactive as well as absorbing fruition experiences [32].
that constantly evolves according to the needs of the customers, as An augmented operator will address the automation of knowledge
the location and the size of each batch is known and the change of which makes it the most flexible and adaptive part in the produc-
the kanban cards takes place automatically in the computer system tion system [33]. He gets an intelligent personal digital assistant
[7], which reacts as a basis for mutual communication [21] with [32], by smart watches [29], the mobile, context-sensitive user
the enterprise stakeholders: customers and suppliers [8]. Quality interface and user-focused assistance systems [34].
problems or failures of the machine are minimized and recovery is Romero et al. [35] present the “operator of the future” or “the
done in a controlled manner [7]. Also, an e-kanban system can operator 4.0” as the smart and skilled operator who performs
bring visibility and improvement of the production and manage- ‘work aided’ by machines if and as needed.
ment of materials into an arrangement where operations are dis-
persed [7]. 3.3.2. Smart Product
In addition, there are still areas where traditional kanban may be
better than e-kanban; this occurs when there is no production in- The role of a product, in the framework of industry 4.0, is changed
formation in the ERP system [8]. from a passive role to an active one [27]; so that the product be-
came smart.
However, while some definitions for smart product exist, it is not
3. The Latest Industrial Revolution: Industry possible to find an agreed upon, generally accepted, and well rec-
4.0 ognized definition of smart products in the literature [36]. Accord-
ing to Rijsdijk and Hultink [37] a smart product is product that
3.1. Industrial Revolutions contain information technology (IT) and that is able to collect,
process, and produce information. In other way, this has a memory
Until today, the industrial environment has known fourth major to store operational data and requirements individually, and is able
revolutions. The first one achieved the mechanization of produc- to request for the required resources and coordinates the produc-
tion using water and steam power; the second industrial revolution tion processes for its completion [38].
introduced mass production by means of electric power; followed
by the digital revolution based on the use of electronics and IT to 3.3.3. Smart Machine
further automate production [25]. Then, the industrial production
According to Alturu et al. [39] a smart machine is defined as “a
is moving from a physical process with IT support to an integrated
machine that knows its capabilities to come up with the most effi-
cyber-physical system of production [26], this characterizes the
cient way to produce a correct part the first time, every time and
fourth industrial revolution, known also as the industry 4.0.
will check and monitor itself using the data to help close the gap
between the designer, manufacturing engineer, and the shop floor”.
3.2. Industry 4.0 It can imply a machine that is better connected, more flexible,
more efficient and safe [40]. Also, it can participate in predictive
In 2011, the approach of industry 4.0 has been presented at the maintenance practices while minimizing its own environmental
Hannover Fair [11, 12]. It was developed in the framework of a footprint and total cost of ownership [40].
project initiated by high-tech strategy of the German government
to promote the computerization of manufacturing [12].
62 International Journal of Engineering & Technology

In addition, a smart machine is able to ensure four levels of intel- priories the production request and to get information on
ligence [41]: Support for humans, repetitive task automation, con- WIP (Work In Progress) level.
text awareness and learning, and self-awareness [41].  Material flow system: the product flow has one way di-
rection; it is transferred from the supplier workstation to
3.3.4. Smart Planner the customer workstation. On the other hand, the full
container/ bin has the same flow direction as the product,
As a result of the connection between the industry 4.0 elements but the empty container circulates in the invers direction.
cited above, the information system can collect data in real time  Machine: the kanban signal allows the communication
from suppliers, customers, products, operators and machines, among the adjacent workstations which are connected
analyses them and planes the activities by taking into considera- via material handling equipment.
tion all requirements to be respected such as deadlines and capaci- Each sub-system contains one or more components that must ac-
ties of machines. Therefore, the processes are optimized in nearly complish its defined tasks and interact with others components for
time [29, 31], the planer system is dynamic and the production the functioning of kanban system. The seven identified compo-
system is more flexible. nents are summarized in figure 2 and their interactions are pre-
sented in figure 3.
4. Kanban System Evolution During the In-
dustrial Revolution
While the second industrial revolution, the kanban system was
developed with the idea to control material flow between work-
stations, using material cards (kanban cards).
The evolution of technology proposes bring solution to some kan-
ban cards limitations ,such as the loss of cards and the demand
that must be regular, and gives birth of a new generation of kan-
ban; the e-kanban system based on a digital signal transferred
from workstation to another trough an ERP system based on RFID
technology.
The fourth industrial revolution is based on the cyber-physical
systems. That means that all objects in a manufacturing environ-
ment are interconnected. The kanban system must follow this Fig. 2: Kanban system components
revolution and be transformed to the kanban 4.0 or smart kanban.
Some industrials proposed solution to this transformation; e-
kanban 4.0, which is a combination of electronic kanban, RFID
and the e-ink that replaces the tag that contain the information
related to a container/bin [42]. Other types of kanban was devel-
oped such as kanban bin or iBin (intelligent bin) based on smart
bins (combination of bin and sensors) able to get information on
inventory level, on real time and communicated it to other work-
station [43]. iBin reports wireless the status to an inventory con-
trol system [44].
The following figure summarized the evolution of kanban system
and its relation with industrial revolutions.

Fig. 3: Kanban functioning in current manufacturing environment

The diagram below shows that the operator is the main actor in the
current functioning of kanban system. He visualizes the order
priority and the WIP level on the kanban board. He is also in
charge of reading the kanban signal and send the work order (idem
transfer order) to the production machine (idem material handling
Fig. 1: Kanban evolution equipment) which is responsible to add value to the product (idem
transfer bin/ container or product according to the transfer order).
5. Analysis of Kanban System Functioning in In case of the use of kanban card, the operator is in charge to
transfer kanban card to the supplier/customer workstation. In some
Current Manufacturing Environment case, he will also add value to product as well as to transfer bin/
container or product.
Based on the description of the kanban system given above, we
can identify four primary sub-systems that constitute this kanban
system which are:
6. Potential Kanban System Functioning for
 Operator: he is the main actor. He supervises the func- Industry 4.0 Environment
tioning of current kanban system.
 Informational system: the kanban signal can be a kanban 6.1. Role of Kanban System Components in the Indus-
card or a digital kanban signal. It has double roles; first try 4.0 Environment
it allows the customer workstation to get information on
the products, and second it orders the production for the In the framework of industry 4.0, the kanban system will be
supplier workstation. A kanban board can be used to changed and transformed to a kanban 4.0 or a smart kanban that
International Journal of Engineering & Technology 63

means that all components cited in Figure 2 should be adapted to 6.2. Potential Object Interactions for the Functioning pf
the new environment. Kanban 4.0
The following table highlights the role/ characteristics of each
kanban system components in the current manufacturing environ- There are two potential functioning of kanban system, the first one
ment as well as its potential role in the industry 4.0 environment. when the product is smart and the second one when the bin is
smart.
Table 1: role/ characteristics of kanban system component in current man-
ufacturing environment as well as in industry 4.0 environment 6.2.1. Case 1: Kanban 4.0 Functioning based on Smart Prod-
Kanban system Role/ characteristics in Potential uct
components current industrial role/characteristics in
environment industry 4.0
In case the product is smart, it will send directly work order to the
environment
Operator  Workforce  Decision maker
production machine which could response to this order by adding
 Supervisor  Problem solver value to the product. Idem, smart product will send transfer order
 Supervisor and to material handling equipment, so that the product could be
controller of activities moved to next workstation. Otherwise, the product can communi-
Kanban signal  Work/transfer order  Digital work/transfer cate its operational information with an augmented operator. This
(card/ digital) information order information later receives also information from smart production machine and
Kanban board  WIP level information  Integrated in the smart material handling equipment. Also, the operator is in charge
 Work order priority Kanban system of ensuring the efficiency of the kanban system functioning.
information The following figure shows the interactions between objects in
Production  Support for Humans,  Autonomous and this case.
machine  Repetitive Task automatic add value
operations
Material  Handling operation  Autonomous and
handling automatic handling
equipment operation
Product  Passive role  Contain operational
information and
Kanban information
 Collect, process and
produce information
 Request for required
resources
 Coordinates the
production process
Container/ bin  Passive role  Contain kanban
information
 Digital WIP level in
Fig. 4: Kanban 4.0 functioning based on smart product
real time

Basing on the assignment of task to each kanban system compo- 6.2.2. Case 2: Kanban System Functioning based on Smart
nents, we will identify its equivalent in industry 4.0 environment. Bin/Container
The following matrix shows the correlation between kanban sys-
tem components and industry 4.0 environment, using as scale: In this case, the work order (idem transfer order) can be sent by
 White case: no correlation smart bin/container/packaging to smart production machine (idem
 Gris case: high correlation smart manufacturing handling equipment) which will then add
value to product (idem transfer bin/container/packaging).
Table 2: correlation matrix between kanban system components and in- The augmented operator will receive information from smart pro-
dustry 4.0 environment duction machine, smart MHE as well as smart
bin/container/packaging, and then he will react on any object in
Industry 4.0 environment
the kanban system, to ensure the efficiency of the kanban system
Kanban system Augmented Smart Smart
components operator machine product
functioning.
Operator The following figure shows the interactions between objects in
Machine this case.
Kanban signal
(card/digital)
Kanban board
Product
Container/bin
Material handling
equipment

The augmented operator can replace the operator who is consid-

ered as a workforce. He can become decision maker, problem
solver, supervisor and controller of activities. The manual tasks
and handling operations can be automated, and carried out by
smart machines.
The smart product can be able to contain, collect, process and
produce information, as well as to trigger work/transfer order. So
the kanban signal and board roles can be integrated in the smart Fig. 5: Kanban 4.0 functioning based on smart bins/containers
product. In some case, the product cannot be smart, so that the
kanban information can be integrated in a smart bin/container.
64 International Journal of Engineering & Technology

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