Loss detection model with kanban card for automobile assembly line

In a modern automobile assembly line, kanban cards or e-kanban cards are used for parts supply. In the line, if a worker would assemble incorrect part to a car body, an inferior product may be shipped to the following production process. Such inferior products will be caught at the inspection process however suspension of production line will occur. In this paper, we propose a loss detection model for a work station which requires installing certain parts. Relationship between number of conveyed car bodies and consumed parts are compared to detect the loss, where we use kanban cards to count parts consumption. We present mathematical models to detect losses and some numerical examples to show stochastic performance of the proposed loss detection model.