Improvement Of Materials Distribution Methods In Mixed-Model Assembly Line Based On JIT Purchasing

Thanks to the diversified and personalized customer needs, multi-varieties andsmall batch production has become main stream. Thus, mix-model production isnecessary where products with similar functions and structures can be produced usingthe same production line.Product models switch frequently in mix-model assembly lines. The key to ensuresmooth production is to send the exact amount of production materials to the assemblylines at the exact time. Traditionally, materials are delivered to the warehouse and sentto the production lines based on the production plan. Such a push distribution strategyresponses slowly to emergency orders. On the other hand, the occupied warehouse areais large due to the large amount of product models in mix-model assembly lines.Based on the mix-model assemble lines for irons in ZPS Company and relevantstudy on material distribution, just in time (JIT) procurement and kanban management,a pull distribution strategy using direct kanban is proposed in this article. Unlike theprevious push distribution strategy for inventory, materials are pull supplied betweenassembly lines and suppliers without other intermediate storage. A new direct kanban isdesigned for the assembly lines. Logistics, information flow and cash flow analysis areperformed for model and process construction. The results show that the occupiedwarehouse area has decreased by70%and the ratio of material quality problems hasdecreased by45%, meanwhile response to emergency orders has been acceleratedsignificantly in production lines.This study has theoretical guiding significance for material distribution inmix-model assembly lines. It can also be a practical guidance for other companiesimplementing such a material distribution strategy.