Selection criterion of production methods used in the Kanban Pull System at Malaysian auto suppliers

Kanban Pull System is a key concept in Lean Manufacturing where production is done based on customer demand. The system, through designated production methods, commands the preceding process to produce only what is needed by the next process in a timely manner using Kanban as a signal to convey instructions to synchronize the production. There are three types of production methods in the Kanban Pull System which are the Kanban Sequencing, Lot Formation and Pattern Production. This paper studies the three types of production method in Kanban Pull System through field research done at Malaysian automotive suppliers in order to understand the factors that influence the selection of the production methods. As a result, a comparison between the production methods are done in terms of the Pull system tools used, its pulling mechanism and its JIT level of effectiveness with regards to reduction in lead time, stock and waste. A summary of criterion and image governing the selection of the production methods is derived from the result gained from this study.