Card-Based Control Systems for a Lean Work Design

Basic Concepts
Highlights
What Is a Production/Service System?
What Is a Business Operation/Process?
What Does a Card-Based Control System Actually Control?
Why Use a Card-Based Control System Rather than the Latest Technology?
Summary: What Card-Based Control Systems Do (And What They Do Not Do) 20
Highlights Revisited

Basic Principles Underpinning a Card-Based Control System
Highlights
Input/Output Control
Visualizing the Stability of the Shop Floor/Station: The Throughput Diagram
Summary: Input/Output Control Underpinning Card-Based Control
Highlights Revisited

Simplified Scheduling through Pool Sequencing and a Shop Floor Dispatching Rule
Highlights
Some Rules for Priority Dispatching on the Shop Floor
Visualizing On-Time Performance: The Order Progress Diagram
Summary: Simplified Scheduling through Priority Dispatching
Highlights Revisited

How to Diagnose a Control Problem?
Highlights
Criterion 1: Make/Produce/Assemble/Build/Serve, etc. To-Stock or To-Order

Criterion 2: The Customer Penetration (Inventory/Order Separation) Point
Criterion 3: Routing Characteristics
Criterion 4: Variability and Uncertainty in Resource Requirements
Summary: Diagnosing the Control Problem
Highlights Revisited

The Inventory Control Problem: Kanban Systems
Highlights
Kanban for the Internal Supply Chain: The Six Rules of Kanban Systems
Work-in-Process Kanban vs. Production Kanban
Kanban for Shop Floor Control
Applicability of Kanban Systems
Summary: Kanban Systems
Highlights Revisited

The Low Variability Order Control Problem: ConWIP
Highlights
ConWIP: How Does It Work?
The Applicability of ConWIP
Summary: ConWIP
Highlights Revisited

Inventory Control Plus Material Requirements Planning for the Order Control Problem: POLCA
Highlights
Paired-Cell Overlapping Loops of Cards with Authorization (POLCA): How Does It Work?
Applicability of POLCA
Summary: POLCA
Highlights Revisited

How to Solve the High Variety Order Control Problem: COBACABANA
Highlights
Control of Balance by Card-Based Navigation (COBACABANA)
COBACABANA: How Does It Work?
Balancing Workloads: The Main Order Release Function of COBACABANA
COBACABANA Recognizes the Difference between Direct and Indirect Work
Simplifying the Need for Processing Time Estimations
COBACABANA and High Processing Time Variability: Starvation Avoidance
Premature Station Idleness and Order Release
Summary: COBACABANA
Highlights Revisited

COBACABANA's Card-Based System for Delivery Time Estimation Highlights
Card-Based Delivery Time Estimation: How Does It Work?
COBACABANA as a Comprehensive System
Using the Salesperson's Display for Output Control
Summary: COBACABANA's Delivery Date Estimation Procedure
Highlights Revisited

Summary: Framework of Applicability
Highlights
Loop Structure and Its Implications for the Application of Card-Based Systems
Card Properties and Their Implications for the Application of Card-Based Systems
The Need for IT Support and Its Implications for the Application of Card-Based Systems
Final Considerations: Nested Card-Based Control Systems
Implementation Information