Card-based delivery date promising in pure flow shops with order release control

Card-based systems are simple, effective means of controlling production. Yet most systems concentrate on controlling the shop floor. They neglect other planning tasks, like estimating short, feasible due dates during customer enquiry management. A card-based version of the workload control concept for job shops – COBACABANA (COntrol of BAlance by CArd-BAsed Navigation) – was proposed in the literature to overcome this shortcoming. COBACABANA uses cards for due date setting and order release, making it a potentially important solution for small shops with limited resources. But many such firms operate as flow shops rather than job shops. Research demonstrated that COBACABANA’s release mechanism must be adapted if applied to a pure flow shop, but its approach to due date setting has not been evaluated in such an environment. We show COBACABANA has the potential to improve pure flow shop performance, but its due date setting procedure should be adapted compared to job shops. In a flow shop, due date estimation can also be further simplified by considering the load awaiting release to the first (gateway) station only while maintaining most performance benefits. The results are important for all card-based systems that aim to stabilise work-in-process, including kanban and ConWIP (Constant Work-in-Process).