Materials Requirement Planning (MRP) and JustIn-Time (JIT)/kanban are two widely used production scheduling and control (PS and C) methodologies in the manufacturing industry. MRP has better planning capabilities, while JIT has superior shop floor control capabilities. MRP is applicable to a wide range of manufacturing companies, while successful JIT/ kanban implementation is generally restricted to repetitive and serial manufacturing. Several hybrid MRP/JIT systems have been proposed by researchers and practitioners to combine the benefits from both methods, while eliminating some of their drawbacks. A few companies have successfully implemented customized hybrid systems. However, there are no 'generic' methods by which JIT/kanban can be combined with MRP. This paper introduces a generic and widely applicable JIT/ kanban-type shop floor extension to MRP. Further, it incorporates specific techniques that eliminate the drawbacks of JIT/kanban and enable it to be used with MRP in a broad range of manufacturing plants. The techniques include: (i) the Kanban Card Controller, which links the MRP output to the JIT/kanban input; (ii) the Kanban Prioritizer, an optimal scheduling methodology, which enables JIT to be used effectively in non-serial production facilities; and (iii) a dynamic lead time estimator which calculates lead time based on the most current shop floor parameters.
All Science Journal Classification (ASJC) codes
- Computer Science Applications
- Strategy and Management
- Management Science and Operations Research
- Industrial and Manufacturing Engineering
- Materials Requirement Planning Mrp
- Production Scheduling