Execution of Pull System and Constant Work-in-Process Using Kanban System—A Case Study

This study presents the implementation of a pull-based production system integrated with a constant work-in-process (CONWIP) approach using the Kanban Methodology in a bearing manufacturing industry. A case study on the UN 3213B bottom roller bearing was conducted, where kanban card design and quantity were determined based on average monthly demand and replenishment time. The methodology involved product-quantity (PQ) analysis, value stream mapping, and stepwise kanban system deployment. As a result of the implementation, the number of kanban cards was reduced from 48 to 38, while work-in-process (WIP) inventory decreased by approximately 20,000 units (27.79%). Replenishment time for the inner ring was reduced from 6.94 to 6.53 days and, for the outer ring, from 6.33 to 5.98 days. The safety factor dropped from 2.5 to 2.0, indicating improved process reliability. The novelty of this work lies in its practical demonstration of integrating kanban with CONWIP for real-time inventory control and lead-time reduction in a high-demand manufacturing setting, offering a scalable model for similar industries.