The Impact of the Kanban Method on the Efficiency of Production Processes in an Automotive Company:A Case Study
Purpose: The purpose of this article is to analyze and evaluate the effectiveness of the Kanban method in improving production processes within an automotive company, with a particular focus on production cycle time and the efficiency of seven production lines. Design/Methodology/Approach: The study employed a case study method and a quantitative analysis of real-world data from an automotive manufacturing company, covering the years 2023–2024. The effectiveness of the Kanban method was evaluated based on an analysis of production cycle times and the Overall Equipment Effectiveness (OEE) metric across seven production lines. The study accounted for the use of electronic Kanban cards, as well as ERP and T-card systems, which support the planning, visualization, and monitoring of production processes. Findings: The analysis conducted demonstrated that the Kanban method contributes to streamlining production processes, shortening production cycle times, and increasing the efficiency of production lines. Between 2023 and 2024, the OEE (Overall Equipment Effectiveness) metric improved across all seven lines analyzed. The average efficiency of all lines in December rose from 84.81% in 2023 to 85.74% in 2024. Furthermore, the implementation of Kanban helps to reduce overproduction and inventory levels, improve the flow of materials and information, and eliminate waste. However, certain limitations of the method were identified, relating to factors such as demand volatility, the need for frequent adjustments to production plans, and the risk of raw material shortages. Practical Implications: The research findings can serve as a basis for implementing and refining the Kanban method within manufacturing enterprises, particularly in the automotive industry. Adopting this approach enables better alignment of production with customer demand, a reduction in warehousing costs, more efficient management of material flow, and faster identification of bottlenecks and downtime. Successful implementation, however, requires effective coordination of supplies, continuous monitoring of demand, and the development of contingency measures to protect against disruptions in the availability of raw materials. Originality/Value: The originality of this article lies in its empirical assessment of the effectiveness of the Kanban method within an actual automotive company, based on data from 2023–2024. By simultaneously analyzing production cycle times and Overall Equipment Effectiveness (OEE) metrics across seven production lines, the study provides a multifaceted evaluation of the outcomes resulting from the implementation of this approach. The value of this work stems from its identification of the practical benefits and limitations of the Kanban method, as well as its confirmation of the method's significance for the continuous improvement of production processes and the enhancement of a company's competitiveness.