An introduction to Kanban using team activities. This is sourced from a presentation with animations that unfortunately don't carry over into SlideShare. Contact me for explanation of how to use the team drawing exercise and template to print the cards.

1. Auditor’s Office Learning by Doing: Kanban
An Interactive Team Activity
Presenter: Robert Simmons, ERP Assistant Project Manager

2. Auditor’s
Office
 Quick Definition of Kanban
 Interactive Production Scenario
 Introduce Kanban Facilitation Tools
 Next Production Scenario
 Review of Results
 Final Production Scenario
 Learnings and Follow-Up Plan
Session Objectives

3. Auditor’s
Office
 A cue-driven method and tools for managing
production-type work.
 Early roots in Toyota manufacturing assembly
line. (Remember TPS Reports?)
 Places emphasis on efficiency, throughput
and quality optimization.
What is Kanban in 30 seconds?

4. Auditor’s
Office
A Quick Game
 Pick a team spokesperson.
 Distribute the tiles and Post-It notes.
 Draw tiles to scale (larger than original).
 Ready….Set…..Draw!

5. Auditor’s
Office
2 minutes…
1 minute…
STOP!!!

6. Auditor’s
Office
Quality Check #1

7. Auditor’s
Office
Make note of the
numbers on your
cards.
Can you make
this picture?
How many?
What happened?
19x2
35
2
6
4
7 8
Production Review 1

8. Auditor’s
Office
 How many Whole Hogs were completed?
 How many waste tiles were generated?
 How many waste tiles were deemed low
quality?
Baseline Metrics

9. Auditor’s
Office
 Visual definition of the concurrent workstreams.
The Kanban Board
Planning In Progress Testing Done
Preparing the
inputs
Work
currently
going on. Can
be further
divided.
Quality
Control.
Goal
conditions
have been
met. This is
the “Done-
Done” state.

10. Auditor’s
Office
 Take a few minutes to design your board.
The Kanban Board
Prepare
Inputs
Draw Parts Quality Check Assembly
• Paper
• Pens
• Highlighter
• Tape
Strategize! Would the
customer
accept the
product?
Put the
squealers
together.

11. Auditor’s
Office
2 minutes…
1 minute…
STOP!!!

12. Auditor’s
Office
 How are the results this time?
 Update your metrics to see the results.
 Whole Hogs:
 Total Waste:
 Cost of Poor Quality:
 Did any teams get creative?
 Did you make re-usable templates?
 Did you recycle poor-quality tiles?
 Did you split your tiles manufacturing into smaller
workstreams?
Production Review 2

13. Auditor’s
Office
Quality Check #2
By understanding more, we can control quality while improving quantity.

14. Auditor’s
Office
 WIP=Work In Process
 Placing limits on each workstream helps
prevent bottlenecks.
 If a limit is reached, resources are expected to
apply efforts to a different workstream.
 A skills matrix may be helpful in determining
the priority of skills when workers are
jumping to a different workstream.
WIP Limits

15. Auditor’s
Office
 Consider the following:
 How many of each part contributes to the final
product?
 How difficult is each part to manufacture?
 Are there any material input constraints?
 How will you know if you hit a WIP limit?
Estimate Your WIP Limits

16. Auditor’s
Office
 Visual cue-ing WIP Limits
The Kanban Board
Prepare
Inputs
Draw Parts Quality Check Assembly

17. Auditor’s
Office
 Turns out that our customers prefer their pigs
have colored hoofs.
 Scenario:
 We need to build a standing inventory of 5
ready-for-color hogs.
 We have demand for 3 green colored hoofs for
every 2 blue colored hoofs.
 15 minutes of planning, 15 minutes of assembly
time.
Customer Demand

18. Auditor’s
Office
BIO-BREAK!!!
Come back in 6 minutes and 20 seconds (or
less).

19. Auditor’s
Office
 Turns out that 80% of our customers prefer
their pigs have colored hoofs.
 Scenario:
 We need to build a standing inventory of 5
ready-for-color hogs.
 We have demand for 3 green colored hoofs for
every 2 blue colored hoofs.
 15 minutes of planning, 15 minutes of assembly
time.
Customer Demand: Planning

20. Auditor’s
Office
 Scenario:
 We need to build a standing inventory of 5 ready-for-
color hogs (20% of overall demand).
 We have demand for 3 green colored hoofs for every
2 blue colored hoofs.
 Produce as many Whole Hogs as possible at the
ratios our customers are demanding.
Customer Demand: Delivery
Don’t stress
too much,
this is still
just a game.

21. Auditor’s
Office
 Whole Hogs:
 Finished Inventory
 Green
 Blue
 CSAT = [1-|(FI – (B+G))/(FI) - .8|] * 100
 Total Waste:
 Cost of Poor Quality:
Final Metrics

22. Auditor’s
Office
 Welcome to Kanban!
 What did you learn? Anything surprising?
 Can you use this in your current work?
 Next Steps:
 Build a Kanban Board or acquire a tool such as
Karbon.
 Schedule a review with a Kanban Sensei (Robert
Simmons, for example).
Summary