TY - JOUR

T1 - Card-based production control

T2 - a review of the control mechanisms underpinning Kanban, ConWIP, POLCA and COBACABANA systems

AU - Thurer, Matthias

AU - Stevenson, Mark

AU - Protzman III, Charles W

N1 - This is an Accepted Manuscript of an article published by Taylor & Francis in Production Planning and Control on 22/05/2016, available online: http://www.tandfonline.com/doi/full/10.1080/09537287.2016.1188224

PY - 2016

Y1 - 2016

N2 - Since the emergence of Kanban, there has been much research into card-based control systems. This has included attempts to improve Kanban and/or develop alternative systems, particularly ConWIP (i.e. Constant Work-In-Process), POLCA (i.e. Paired-cell Overlapping Loops of Cards with Authorisation) and COBACABANA (i.e. Control of Balance by Card-Based Navigation). Yet, to date, no unifying review of the mechanisms underpinning these systems has been presented. As a consequence, managers are not provided with sufficient support for choosing an appropriate system for their shop; and researchers lack a clear picture of how the mechanisms compare, leading to several misconceptions. This paper reviews the control mechanisms underpinning the Kanban, ConWIP, POLCA and COBACABANA systems. By comparing the ‘control mechanism’ (i.e. the loop structure and card properties) and ‘contextual factors’ (i.e. routing variability, processing time variability, and whether stations are decoupled by inventory or the flow of jobs is controlled), we provide managers with guidance on which system to choose. For research, we show for example that most criticisms put forward against Kanban systems, e.g. to justify the development of ConWIP, POLCA or COBACABANA, only apply to work-in-process Kanban systems and not to production Kanban systems. Future research directions for each control system are outlined.

AB - Since the emergence of Kanban, there has been much research into card-based control systems. This has included attempts to improve Kanban and/or develop alternative systems, particularly ConWIP (i.e. Constant Work-In-Process), POLCA (i.e. Paired-cell Overlapping Loops of Cards with Authorisation) and COBACABANA (i.e. Control of Balance by Card-Based Navigation). Yet, to date, no unifying review of the mechanisms underpinning these systems has been presented. As a consequence, managers are not provided with sufficient support for choosing an appropriate system for their shop; and researchers lack a clear picture of how the mechanisms compare, leading to several misconceptions. This paper reviews the control mechanisms underpinning the Kanban, ConWIP, POLCA and COBACABANA systems. By comparing the ‘control mechanism’ (i.e. the loop structure and card properties) and ‘contextual factors’ (i.e. routing variability, processing time variability, and whether stations are decoupled by inventory or the flow of jobs is controlled), we provide managers with guidance on which system to choose. For research, we show for example that most criticisms put forward against Kanban systems, e.g. to justify the development of ConWIP, POLCA or COBACABANA, only apply to work-in-process Kanban systems and not to production Kanban systems. Future research directions for each control system are outlined.

KW - Card-based control

KW - Kanban

KW - ConWIP

KW - POLCA

KW - COBACABANA

U2 - 10.1080/09537287.2016.1188224

DO - 10.1080/09537287.2016.1188224

M3 - Journal article

VL - 27

SP - 1143

EP - 1157

JO - Production Planning and Control

JF - Production Planning and Control

SN - 0953-7287

IS - 14

ER -