Pull System & Kanban Cards
a Tool of Lean Manufacturing
CAS Medical System’s
Route to World Class Manufacturing
Value Stream 5s Flexible Small Lot Rapid Response
Mapping Evaluation Work Force Production to Change
Layout Visual Setup One Piece Short Cycle Highest
Changes Controls Reductions Flow Manufacturing Quality
Work Takt Time Systems Kaizen
Push vs. Pull Inventory Systems
Push – Whether you need it or not you’re getting
it anyway. (Old school)
100 → 100 → 100 → 100 → 100 → 10
* Based on the customers demand you have 90% excess inventory
Push vs. Pull Inventory Systems
Pull – You get it only when you ask for it.
Cust. Demand → Production → Stock → Purchasing → Supplier
10 → 10 → 20 → 10 → 10
* Based on the customers demand you have 50% excess inventory,
but you have 40% less inventory compared to the Push system.
Pull Systems are:
Simple and Visual
Executed by shop floor employees
Runs on customer demand rates
Push Systems are:
Executed by Production Control &
Runs on forecasted dates & sales history
Types of Pull Signals
Painted or taped squares on the floor
Level Indicator Signs
Is considered to be the best Pull Signal
system you can use to control your inventory
dollars, prevent part shortages and improve
your cash flow.
So what is Kanban?
Kanban is a Japanese word that means “card”
It was originated by Japan’s Toyota Co.
It is a tool of lean manufacturing that’s used to apply JIT
(Just In time) inventory.
It is a type of reorder point system.
It is not a zero inventory system
It is a manual technique that is in the hands & controlled
by the production workers.
Keys to a successful Kanban system
It’s not the cards themselves, but the
discipline performed by the employees
Material is not moved or produced without
The emphasis is not to balance capacity, but
to balance flow
Made To Order Kanban Card
750E-2NL VA MONITOR ETXT WA
SUB # 03-08-0619
Today’s Purchasing Card
PURCHASING INVENTORY KANBAN CARD
P/N: 28-02-0122 Buyer Code: 01
Description: Foam Pad 2 x ¼”
Used On: 511’s
# of KB Cards: 1
Reorder Point: 25
Reorder Qty: 100
Date Ordered: Vendor: EAR Specialty
Lead Time: 42 days Vendor#:
Delivery Date: Notes:
**Issue to Work Center:
What 2 items are missing on this Internal work cell
STOCK TRANSFER CARD
PART NUMBER: 28-02-0422
DESCRIPTION: FOOT PAD
REORDER QTY-PCS: 60
DELIVER TO CELL: 740 / 750
1)Reorder point quantity
2) # of Kanban cards
Kanban Card Ground Rules 1 - 5
1) Operators can change KB card quantities as demand increases or
2) In a 2 bin card system, complete 1 bin first before going into the
2nd bin. Don’t double dip.
3) Putting both KB cards into 1 bin to save space is OK, but you will
have to manually monitor your actual counts so you know when to
hand in the first card for replenishment
4) KB quantities for large parts that utilize a lot of space should be set
to a 1 day’s supply. Small parts should not exceed more then a
5) Change piece quantity on some cards to number of boxes. This
will save you space and will save the stock person time in issuing.
Kanban Card Ground Rules 6-10
6) We should never see empty bins w/ KB cards in them; Never see
KB cards lying on an empty shelf; Never see KB cards lying on the
floor; Never see KB cards unattached to materials.
7) Lost KB cards will happen. Make sure you report it so a new card
can be made ASAP.
8) Determine ways to attach KB cards to materials to prevent them
from getting lost & misplaced. (zip-lock bags, scotch tape,
magnetic clips, paper clips, adhesive pouches)
9) Stock person & cell operators must make sure that KB cards are
placed in proper positioning for timely replenishment from stock.
10) Keep KB cards with the item. Don’t keep them hidden in folders,
drawers, etc. They should be visual.
Conclude this presentation with:
The Family Milk Story