ENHANCING LEAN MANUFACTURING THROUGH DIGITAL E-KANBAN INTEGRATION AND INDUSTRIAL AUTOMATION
Abstract
The traditional Kanban system has long served as a cornerstone in lean manufacturing for managing inventory and production flow. However, its limitations in real-time tracking, responsiveness, and data visibility make it less effective. This research presents the design and implementation of an Electronic Kanban (E-Kanban) system integrated with a programmable logic controller (PLC), infrared (IR) sensors, and real-time data visualization via Siemens S7-200 and OPC Expert. The system was deployed on a simulated assembly line with clearly defined workstations to evaluate improvements in throughput, cycle time, and work-in-process (WIP). Results indicate a 17% reduction in cycle time and a 21% increase in throughput, demonstrating the effectiveness of the proposed E-Kanban system. The integration of automation and digital tracking significantly reduced manual errors and enhanced decision-making. Future extensions include the integration of artificial intelligence (AI) and predictive analytics for proactive inventory management.
