Rolling Kanban: a new visual tool to schedule family batch manufacturing processes with kanban

Rolling Kanban is the name of a kanban management methodology for batch processes manufacturing environment. Proposed in the early 2000s by FESTO Consulting, for two decades we have lost knowledge both from operative and scientific point of view. Basically, Rolling Kanban means a visual planning methodology based on the production of product-families and variants where: (i) set-up times are reduced between the products of the same family, and (ii) relevant times (dozens of minutes if not even hours) must be considered for changeover between products of different families. In addition, the cyclic production sequence between different product families cannot be maintained. Considering that very few technical information and documents are available about this approach, the main objective of this paper is to retrieve and present, for the first time to the scientific community, the Rolling Kanban methodology. Besides, a real industrial implementation concerning a manufacturer of domestic fittings is discussed as a case study. More specifically, two novel versions of the original Rolling Kanban technique are fully presented to effectively overcome certain limits and criticalities found during its operative use, such as the difficulty to realize a pull production, considering increased set-up time for changeover between products of different families.