Kanban explained - both for manufacturing processes as well as non-manufacturing: service, project management, etc. Kanban really isn't as complicated of a concept as people make it out to be. It's pretty much all one model applied in different ways. This presentation has some theory, some examples, and some advice & quotes related to the tool

1. Kanban Explained
(includes other processes besides picking component parts)
Kanban (“KAHN-BAHN”) – Japanese word meaning “signboard or billboard” – a
scheduling system to ensure that only what is needed is produced

2. The general idea of Kanban
2. Supplier pulls the
order info to produce
to the order
Supplier
1. Customer logs an order in an
order system
Order
Information
Customer
3. Supplier delivers exactly
what the customer ordered
Each action is triggered by the delivery of the order itself, requiring
less effort to manage the information and timing of tasks

3. Some different Kanban methods
Central information spot
• “Kanban Board” – physical board showing order status
• SharePoint Task List (tasks are “orders”)
Physical movement of a bin or card
• Empty, labeled bin physically delivered to the supplier
• Card with order information delivered to supplier

4. Example: Picking large sheet metal parts
with forklift (at Kirby Risk Service Center)
2. Forklift driver picks the
part, and applies a label to it
showing the KR Part #
Forklift Driver
1. Parts picker writes up a
sheet metal pick ticket
Parts Picking
Card
Parts picker
Wow, sure glad I can
drive this forklift…
WITH MY MIND
3. Forklift driver delivers part
to job staging area

5. Example: Kanban project board
What it looks like:
Done
2. Task owner moves post-it into
“In Process”, and works on task
LARRY
MOE
CURLY
Backlog
In
Process
1. Project manager puts task postit onto “Backlog” section of
Kanban board
Task owner
Kanban
Board
Task
Assigner
= regular task
= hot task
3. Task owner moves post-it to
“done” (and notifies project
manager, if it is hot)
4. Team meets in regular accountability
meeting to…
•
•
•
Discuss issues (interruptions, barriers to flow, etc.)
Problem solve together
Plan further action

6. Kanban Project Board, ctd.
Close-up view of the board
LARRY
MOE
CURLY
Backlog
In Process
Done
Color Code
= regular task
= hot task

7. Example: SharePoint Task List
1. Task manager creates
task in SharePoint list
2. Task owner marks
task as “In Process”
Task owner
SharePoint
Task List
3. Task owner marks task
as “Complete”
Task
Manager
4. Task manager notified

8. How to make an electronic Kanban
system actually work…make it visual!
In electronic systems, tasks can tend to get hidden in the sea of electronic
inventory: folders, websites, spreadsheets, databases, etc. Here are some
ways to make it visual…
1.
2.
3.
4.
Automatic email gets sent to task list manager when changes are
made to a task
Regular process for task owners & task manager to check task lists
When a task owner marks a task as “in process”, they make a note
which they visually display at their workstation
Use dashboard(s) to draw together information from multiple info
sources to a single place

9. Best Practices with physical Kanban bins
• Three-bin system – A bin is kept at the initial
demand point, the inventory control point,
and at the supplier
(bins have a removable card with product details and
other needed information)
• Calculate just enough Kanban cards for each
product
• Use a heijunka box:
Regular time increments (ex: 30 min)
Info from:
http://en.wikipedia.org/wiki/Kanban
http://en.wikipedia.org/wiki/Heijunka_box
Products
(a.k.a. load-leveling box)

10. Some rules used by Toyota
1. Do not send defective products to the
subsequent process.
2. The subsequent process comes to withdraw only
what is needed.
3. Produce only the exact quantity that was
withdrawn by the subsequent process.
4. Level the production.
5. Kanban is a means of fine tuning.
6. Stabilize and rationalize the process.
Info from http://en.wikipedia.org/wiki/Kanban

11. How Kanban helps with common
problems
Problem
How Kanban helps
Bottlenecks / Multitasking /
Task-switching
Helps process users to do one-piece-flow, which
cuts down on WIP
People stressed because too
much is demanded on them
Makes work visual, which naturally creates more
accountability, and allows employees to better
level out the work
Communication breakdowns
Manages the communication task itself, so there’s
much lower risk of forgetting to notify the people
who need updates
Kanban is a great tool, but just like a hammer, there are times when it works well by itself to fix
an obvious problem (ex: a nail sticking out of a cabinet), but there are times when a lot more
than a hammer is needed (ex: improving on time delivery of cabinets). Kanban systems can
help to improve the flow of information or products in a workcenter or team, but it is a tool
that is best deployed aligned with a company-wide improvement program
“Just using Lean tools is like looking after an animal for years without knowing if it
was a dog, rabbit, leopard or a sick rat” –Author Stephen Parry

12. And now for something completely different…
(Images from www.leanmemes.com)

13. About the author:
Brent Brewington
Quality Specialist
Blog:
Twitter:
LinkedIn:
About.me:
QualityIdeasGuy.com
twitter.com/BrentBrewington
LinkedIn.com/in/BrentBrewington
about.me/BrentBrewington
You are more than welcome to connect with me and get in
touch. I’d love to listen to your ideas, and to share some of mine
How I found my way into quality: While managing a Korean/Japanese restaurant serving Purdue students, I started
to lean up the order management, production, and service processes, and realized that I wanted to do that for a
living: improving processes and systems so that they are easier for people to use, and increase in performance.
After doing some soul-searching and intense networking, I landed a job in quality at a tier one supplier to
Caterpillar, and haven’t looked back since!