Electronic Kanban

DEVELOPING AND BUILDING A LEAN BASED
RFID ELECTRONIC KANBAN PROTOTYPE

A Thesis presented to
The Faculty of California Polytechnic State University

In Partial Fulfillment of the Requirements for the Degree
Master of Science in Industrial Engineering

by
Ryan T. Chang
June 2012

© 2012
Ryan Chang
ALL RIGHTS RESERVED
COMMITTEE MEMBERSHIP ii TITLE

DEVELOPING AND BUILDING A LEAN BASED RFID
ELECTRONIC KANBAN PROTOTYPE

AUTHOR:

Ryan T. Chang

DATE SUBMITTED:

June 2012

COMMITTEE CHAIR:

Dr. Tali Freed, Professor, Industrial and
Manufacturing Engineering

COMMITTEE MEMBER:

Dr. Lizabeth Schlemer, Associate Professor, Industrial and
Manufacturing Engineering

COMMITTEE MEMBER:

Dr. Tao Yang, Professor, Industrial and
Manufacturing Engineering

ABSTRACT
DEVELOPING AND BUILDING A LEAN BASED iii RFID ELECTRONIC KANBAN PROTOTYPE
Ryan T. Chang
The kanban system is a popular Toyota lean manufacturing tool used to help facilitate material movement between workstations and suppliers. Since the 1950’s, the original kanban system has undergone many different variations due to the advancement of technology and unique company implementation. This report focuses on the development and building of a new variation of the kanban system using lean principles while integrating radio frequency identification (RFID) technology with a fully electronic based kanban card system. This new type of kanban system will be called the RFID E-Kanban in this report. Since the lean philosophy is to reduce non-value added waste to a process, the new prototype kanban system meets four design objectives that are consistent with the principles of lean and the original purpose of the kanban system.
1. The RFID E-Kanban prototype must support the process of continuous improvement
2. The RFID E-Kanban prototype must reduce overall non-value added waste to the material flow process
3. The RFID E-Kanban prototype must be intuitive and

References: [2] Lage Junior, M., & Godinho Filho., M. (2010). Variations of the Kanban system: Literature review and classification Vol. 36, No. 1, 1995, pp. 60-64. [4] Patti, A. L. and Narsing, A. (2008) RFID and Lean: Friends or Foes?, Journal of Business and Economics Research, 6(2):83-90. [5] Su, Weixing, Lianbo Ma, Kunyuan Hu, and Lei Zhang. "A Research on Integrated Application of RFID based Lean Manufacturing." Control and Decision Conference (2009): [6] Sanghera, Paul. RFID+ Study Guide and Practice Exam. Rockland, MA: Syngress, 2007. [9] J. Collins, “DaimlerChrysler Putting RFID Tags in Kanban Cards,” RFID Journal, June 7, 2006, http://www.rfidjournal.com/article/view/2405/1 http://www.rfidjournal.com/article/view/3293 [11] ZhangY, PingyuJ, HuangG (2008)RFID-based Smart Kanbans for Just-in- Time [13] "The Cal Poly RFID Lab." The Cal Poly RFID Lab. N.p., n.d. Web. 17 Mar. 2012. Journal of Production Research 15.6 (1977): 553-64. Print. [15] Riezebos, Jan, and Warse Klingenberg. "Advancing Lean Manufacturing, the Role of IT." Computers in Industry 60.4 (2009): 235-36 International Journal of the Computer, the Internet and Management, 17.SP1 (2009). Print. [17] N. Huber, K. Michael, and L. McCathie. Barriers to RFID adoption in the supply chain. In RFID Eurasia, 2007 1st Annual, pages 1{6, 2007. [20] Kelepouris, Thomas, Katerina Pramatari, and Georgios Doukidis. "RFID-enabled Traceability in the Food Supply Chain." Industrial Management & Data Systems 107.2 (2007): [22] Potter, Dick, Ron Bowman, and Laura Peters. "Cost Per Wafer." Cost Effective IC Manufacturing, 1998-1999