Abstract
Kanban system as a pull system has been the center of attention on inventory and WIP reduction for many years. Since the pull system could be applied only to repetitive type of production, it should be meaningful if some scheduling method could attain the same WIP level with the pull system's performance. Scheduling is a universal method both for repetitive and non-repetitive production. Therefore, the scheduling method becomes effective to get shorter total lead time for non-repetitive production environment such as a Make-To-Order type factory which has long multiple processes. This paper shows how the FCS (Finite Capacity Scheduling) system is applied for getting the same production instructions and WIP results with the case of using "one-card system" which is one of the typical pull systems. The comparison is done under the conditions of a certain demand model between a one-card system and an event-based FCS with backward pass. The outcome of the hand simulation shows that each WIP between processes is converged to the same volume with the case of using the pull system. Although FCS could not overcome the pull system in the aspect of WIP reduction, a market-based production system where materials move only if there is a demand for it would be realized in any production environment by utilizing a scheduling system. Most Make-To-Order type factories, which have long multiple processes have used a preplanning-based system so far. However, the system could be more demand-pull system by adopting the FCS system. To make sure, the scheduling system should not be considered as a planning system. Rather, it is an information system to transmit the customers' requirements.
