Development of a digital green kanban system for the finished goods warehouse in the snack food industry
Keywords:
Digital kanban, Green manufacturing, Lean production, Warehouse managementAbstract
In the Industry 4.0 era, increasing the efficiency and speed of information flow is a crucial factor in maintaining the competitiveness of manufacturing companies, particularly in the snack food industry, which is characterized by large-scale, repetitive production and high volumes of finished goods. These characteristics pose significant challenges in maintaining the accuracy of shipped goods. One concept commonly applied to improve the efficiency and accuracy of the shipping process is the kanban system, as part of the lean manufacturing philosophy. However, the conventional kanban system still results in various inefficiencies, including data recording errors, excessive paper usage, and the misplacement of finished goods during shipping, which caused company losses amounting to IDR 357,508,500.00 between February and March 2025. This study employed a Research and Development (R&D) approach to design a Digital Green Kanban System framework integrated with an Enterprise Resource Planning (ERP) system. The research stages included needs analysis, mapping of material and information flows, and production flow design, resulting in a computer-network-based Digital Green Kanban System framework. Data were collected through observations of the production process, interviews with operators and logistics staff, and analysis of historical shipping data. The design results indicate that the proposed Digital Green Kanban System framework can support kanban lot-size control, production instruction scheduling, and direct data integration with the ERP system. The framework also improves information flow and traceability of finished goods, potentially reducing the risk of shipping errors. The main contribution of this research is the development of a Digital Green Kanban System framework specifically designed for internal production systems operating on a dedicated production line, serving as a strategic step toward process digitization and enhanced operational efficiency.
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