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What is the optimal number of Kanban cards to use in Lean Manufacturing?

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Kanban cards are a key tool in Lean Manufacturing to manage the flow of materials and information in a production system. They are visual signals that trigger actions and indicate the status of work processes. But how many Kanban cards should you use to achieve optimal efficiency and quality? In this article, you will learn about the factors that affect the number of Kanban cards, the benefits and drawbacks of using more or less cards, and the methods to calculate and adjust the optimal number of cards for your situation.

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Yasir Waseem

Lean Manufacturing Expert | Certified 5S Auditor & Practitioner | LSSBB | Certified TPM practitioner | CQP | CKP | CLMP
Ganesh Malani

Managing Partner at Apex Hatchers | Strategy & Innovation
Rafael Alves Zvir

Sr. Continuous Improvement Analyst | LSS Master Black Belt

1 What are Kanban cards?

Kanban cards are physical or digital cards that represent a unit of work or a batch of materials in a Kanban system. A Kanban system is a pull-based approach that limits the amount of work in progress (WIP) and synchronizes the demand and supply of different stages in a value stream. Each Kanban card contains information such as the type, quantity, source, and destination of the work or material. Kanban cards are attached to containers, racks, boards, or screens to communicate the status and availability of the work or material.

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Rafael Alves Zvir

Sr. Continuous Improvement Analyst | LSS Master Black Belt
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é parte de um método que aborda a parte visual para gerenciamento de projetos e fluxos de trabalho. Eles representam tarefas em um quadro visual, com informa??es relevantes, movendo-se entre colunas que representam estágios do processo. O método é usado em diversos contextos para otimizar eficiência e visualizar o progresso das tarefas.

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Marcello Soares

CEO & Founder - Labone Consultoria e Treinamentos | Lean Six Sigma Master Black Belt | Trainings and Consulting | Top Lean Manufacturing & Lean Six Sigma Voice | Leadership Development Expert
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Como especialista em Melhoria Contínua, recomendo considerar diversos fatores ao determinar o número ideal de Kanban cards em Lean Manufacturing: - Demanda Variável: Ajuste o número de cart?es conforme a flutua??o da demanda. - Lead Time: Baseie-se na análise do lead time para garantir um fluxo eficiente. - Capacidade da Equipe: Considere a capacidade da equipe para atender às demandas de produ??o. - Varia??es de Processo: Leve em conta varia??es no processo para evitar gargalos. A personaliza??o conforme as necessidades específicas é crucial.

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2 Why does the number of Kanban cards matter?

The number of Kanban cards in a Kanban system determines the level of WIP and inventory in the production system. WIP and inventory are forms of waste that increase costs, reduce quality, and delay delivery. By limiting the number of Kanban cards, you can reduce the WIP and inventory and create a smoother and faster flow of value to the customer. However, if you use too few Kanban cards, you may create bottlenecks, shortages, and interruptions in the production system. You may also lose flexibility and responsiveness to changes in demand or supply. Therefore, finding the optimal number of Kanban cards is a balance between minimizing waste and maximizing flow.

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3 What factors affect the number of Kanban cards?

The optimal number of Kanban cards depends on a variety of factors, such as the demand rate of the customer or the downstream process, the lead time or cycle time of the supplier or the upstream process, and the variability or uncertainty of the demand and supply. Additionally, it is important to consider the size or quantity of the work or material represented by each card, the safety stock or buffer level required to prevent stockouts or delays, and the replenishment frequency or interval of the work or material. These factors can differ depending on the type, complexity, and scale of the production system and the products or services involved.

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Yasir Waseem

Lean Manufacturing Expert | Certified 5S Auditor & Practitioner | LSSBB | Certified TPM practitioner | CQP | CKP | CLMP
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The number of Kanban cards in a system is influenced by various factors. Firstly, it's impacted by the desired production flow rate and customer demand variability. Complex processes with multiple stages may require more cards. Inventory and lead time goals also affect card numbers, aiming for optimized stock levels. Additionally, considering the size of batches and replenishment frequency impacts the card count. The physical size or volume of items and the storage capacity also dictate the card quantity. Finally, variations in supplier lead times and transportation intervals contribute to determining the appropriate number of Kanban cards within the system.

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4 How to calculate the optimal number of Kanban cards?

Calculating the optimal number of Kanban cards for a given situation is possible with the following formula: Number of Kanban cards = (Demand rate x Lead time x Safety factor) / Batch size. Demand rate refers to the average number of units or batches required by the customer or the downstream process per unit of time; Lead time is the average time it takes for the supplier or the upstream process to produce and deliver one unit or batch; Safety factor is a multiplier that accounts for the variability or uncertainty of the demand and supply; and Batch size is the number of units or batches represented by one Kanban card. This formula can be applied to different types of Kanban cards, such as Withdrawal cards, Production cards, Supplier cards, and Signal cards. Withdrawal cards authorize movement from one location to another, Production cards authorize work or material production at a location, Supplier cards authorize replenishment from an external supplier, and Signal cards trigger production or replenishment at a location.

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Ganesh Malani

Managing Partner at Apex Hatchers | Strategy & Innovation
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The endless debate over optimal Kanban quantities exemplifies how Lean often fixates on the trivial at the expense of the profound. We obsess over the digits on cards while ignoring dysfunctional cultures underneath. Does a four-card limit spark joy or simply shift waste elsewhere? Kanban is not about statistical modeling, but freeing workers to reveal problems. Quantities are a means, not the end. Stop worshipping numbers and start empowering people. Enable teams to pull work as they see fit, not according to some top-down theory. Seek to enhance transparency, communication, and ownership. Great leaders don't dictate standard work, but develop flexible people able to adapt to dynamic challenges.

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5 How to adjust the optimal number of Kanban cards?

The optimal number of Kanban cards may change over time due to fluctuations in demand, supply, or other factors. Thus, it is important to monitor and review the performance and efficiency of the Kanban system and adjust the number of Kanban cards accordingly. Indicators that suggest the need for adjustment include excess or shortage of work or material at any stage or location, frequent or prolonged idle time or waiting time for workers or machines, high or low inventory turnover or turnover ratio, high or low customer satisfaction or feedback, and high or low defect rate or quality issues. To adjust the number of cards, you can modify one or more variables such as demand rate, lead time, safety factor, and batch size. The goal is to reach a state of continuous improvement and alignment with customer value and expectations.

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Diogenes Espindola, MSc.

Integrated Lean Six Sigma Manager (TPM)
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The optimal number of Kanban cards in a system depends on specific characteristics of the process, such as production capacity, cycle time, and task variability. A common approach is to use the Economic Order Quantity (EOQ) formula, considering the balance between setup costs and inventory holding costs. To calculate the optimal number of Kanban cards, you can adapt the EOQ formula to the Kanban context, taking into account demand, cycle time, and associated costs. Reference: Anderson, D. J. (2010). Kanban: Successful Evolutionary Change for Your Technology Business. Blue Hole Press.

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6 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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What is the optimal number of Kanban cards to use in Lean Manufacturing?

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3

4

5

6

1 What are Kanban cards?

2 Why does the number of Kanban cards matter?

3 What factors affect the number of Kanban cards?

4 How to calculate the optimal number of Kanban cards?

5 How to adjust the optimal number of Kanban cards?

6 Here’s what else to consider

Lean Manufacturing

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What is the optimal number of Kanban cards to use in Lean Manufacturing?

1

2

3

4

5

6

1 What are Kanban cards?

2 Why does the number of Kanban cards matter?

3 What factors affect the number of Kanban cards?

4 How to calculate the optimal number of Kanban cards?

5 How to adjust the optimal number of Kanban cards?

6 Here’s what else to consider

Lean Manufacturing

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