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    Fig. 3). The shelves were organized to have small stocks of
    each reference. These shelves have a little inclination and a
    few rollers, so that process of storage is more ergonomic
    and the picking reliable. The material must be fed on the
    back, whereas the picking of material must be realized on
    the front. With this system, FIFO is guaranteed and the
    material is consumed in the order that it is received.
    The information of kanban cards are: (1) name and
    reference of the component: there are components with
    equal name but different references, so the reference is
    fundamental to identify every component; (2) name of the
    piece: EV6; (3) trip of the card: although the normal thing
    is that kanban circuit have a place of beginning and other of
    end, in this case, it does not happen this way, kanban only
    circulates along the washing machine; (4) quantity and
    special quantity: these quantities reflect the quantity of
    original packing and another one for special orders which
    the received quantity does not coincide with that of original
    packing; (5) number of card and quantity of cards in
    circulation: cards are numbered correlatively. Figure 4
    illustrates it.
    Another problem was the definition of the number of
    cards because although there are known mathematical
    formulae that define the exact number, the initial situation
    was not very stable for the processes, so in certain
    components, the requirements for extra stock was estab-
    lished to cover the delays that these processes could
    provoke. This definition is based on the experience of the
    planners and for a moment of production at which the line
    was not employed to 100% of its capacity. As this is a
    flexible system, introducing or eliminating kanban cards is
    possible to simply regulate the number of stock between the
    processes [28].
    Fig. 5 Kanban shelve with two kanban circuits
    Fig. 6 Kanban circuit diagram
    954 Int J Adv Manuf Technol (2009) 43:949–9586.2 Kanban circuit 1: shelves kanban in washing machine 1
    To support the control of stock once received and to
    facilitate the material requirements to the external store, a
    special kanban has been designed, named Shelves Kanban.
    The cards do not arrive to the provider because, in this first
    phase, providers have not been included in the system, only
    they have been informed about the need to receive lots as
    the quantity of original packing to minimize the risks that
    the manipulation supposes. The factory is connected with
    this external store by electronic way and the request of
    material is reported in the kanban.
    The number of cards is limited, according to the quantity
    by lot and of the necessary stock. Every lot that is received
    is accompanied by a kanban card and is stored in the
    shelves of washing machine #1 depositing the receptacles
    on the back and later, when material is needed, taking the
    material from the front following FIFO. The associated
    kanban card is taken too and it is placed in a receptacle of
    methacrylate (see Fig. 3) attached to the side of the shelves.
    At the beginning of every work shift, the person in
    charge of the washing machine will gather all the cards that
    exist in the kanban receptacle and will order to the external
    store the material that indicate the cards and in the quantity
    that the same ones should indicate. It is important to use the
    material in the quantities of the original packing to avoid
    problems at the time of realizing orders.
    As seen in Fig. 1, cups have a first machining before
    they arrive at the washing machine. Although this process
    is not realized near the washing machine, only the
    personnel of this one are authorized to realize requests of
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