Application of lean manufacturing tools in high mix / Low Volume (HMLV) environments: A review of Kanban, POLCA, and COBACA BANA

Abstract

Objectives: The primary objective of this paper is to explore the application of lean manufacturing tools,specifically in HMLV environments, and evaluate their effectiveness in addressing the unique challengesfaced in such settings. Data and Methods: To this end, we will focus on investigating the advantagesand disadvantages of different lean tools, with particular emphasis on kanban, and explore alternativematerial flow control tools such as POLCA (Paired-cell Overlapping Loops of Cards with Authorization)and COBACABANA (Control of Balance by Card Based Navigation) for their potential in HMLVenvironments. Results: Understanding the challenges and opportunitiesassociated with implementinglean manufacturing in HMLV environments is critical for organizations seeking to enhance operationalefficiency, reduce waste, and optimize production processes. By examining the limitations of kanban inHMLV settings and exploring alternative tools, this research aims to provide valuable insights andrecommendations. Conclusions: Lean manufacturing can be applied effectively in high mix / low volume(HMLV) environments by using alternative material flow control tools such as POLCA andCOBACABANA. These tools can help organizations enhance operational efficiency, reduce waste, andoptimize production processes.Keywords:Lean Manufacturing, High Mix / Low Volume (HMLV), Kanban, POLCA, COBACABANA,Material Flow Control