4.2. e-kanban system
The e-kanban system was developed as a strategy to solve the
problem. This web-based system obtains real-time body data from
the MES. The system functions specifically as an interface with the
ERP and MES to calculate the sub-daily requirements as shown in
Fig. 3. The MES receives the scheduling information for production
planning through the ERP system and the MES provides the quantity
of real-time online bodies or WIP to the e-kanban system. The
rapid information flow is fully visible from forecast to the MES. The
automatic data transfer to the e-kanban also will ensure the accuracy
of the data. No manual data maintenance is required in e-kanban
which reduces human errors and avoids manipulation. The
latest WIP sequence from the MES will enable suppliers and third
party logistics (3PL) to supply parts on a Just In Time basis.
Figs. 4 and 5 present an overview of the e-kanban system and
the e-kanban operational flow respectively. The e-kanban system
links to the Bill Of Material (BOM) from the ERP. The combination
of information from the e-kanban database and the BOM (i.e. basic
information, packaging information, logistics information and
order information) are used to convert the body data into a partby-
part format. If there are any additional orders, the user will fill
up the order form in the e-kanban system. The quantity of parts
usage per car and the quantity of parts per packaging process are
also provided.
The system will calculate the required quantities of parts and
the quantities of parts for order. The information for the required
quantity of parts will appear in the supply form via the web portal
such that the Production Control Department in the temporary
storage area can supply parts to the supermarket area at the specific
time at the right place with the required quantity. In the
ordering flow, after the system generates the fixed delivery time
and estimates the time arrival for each part, the system will order
a specific time and submit the information to the suppliers or 3PL
by uploading the ordering format to the ERP. The suppliers view
the order on the web and print the order form as shown in
Fig. 5. The supplier will deliver the parts to the manufacturer
according to the quantity ordered at a specific time.
Many benefits are provided by the e-kanban system. Accurate
information can be obtained by avoiding the manual part ordering
operations that lead to human error. The information is also applied
as a web-based system with real-time data which makes it simpler
for the manufacturer and suppliers to monitor the parts ordering
and delivery processes. The system also reduces the job scope for
the shopping man and eliminates forms that must be filled out.