What is the role of kanban in manufacturing operations?

1 What is kanban?

Kanban is a method of controlling the flow of materials and information in a production system. It uses cards, boards, bins, or other signals to indicate the status and demand of each stage of the process. Kanban helps to synchronize the activities of different teams and departments, avoid overproduction and inventory, and identify and eliminate bottlenecks and errors. Kanban is based on the principle of pull, which means that each stage only produces what the next stage requests, rather than pushing excess output.

2 How does kanban work?

Kanban works by creating a visual representation of the production process, from the customer order to the final delivery. Each stage of the process has a kanban board, which shows the tasks, priorities, and progress of the work. Each task is represented by a kanban card, which contains the specifications, requirements, and due date of the work. The kanban cards move along the board as the work progresses, from the "to do" column to the "done" column. The kanban cards also act as triggers for replenishing materials and resources, as they signal when a stage is running low or has completed its work.

3 What are the benefits of kanban?

Kanban can provide numerous advantages for manufacturing operations, such as reducing waste and inventory, improving quality and customer satisfaction, increasing efficiency and productivity, enhancing collaboration and communication, and fostering continuous improvement. It does this by preventing overproduction and overstocking of materials and products, ensuring that the work meets customer specifications and deadlines, streamlining the workflow to eliminate delays and interruptions, making the work visible and transparent to all stakeholders, and allowing for feedback and adjustments to the process.

4 What are the challenges of kanban?

Kanban is not a one-size-fits-all solution for manufacturing operations and requires a culture of trust, cooperation, and commitment to the customer. It also necessitates a careful analysis and design of the production system, as well as constant monitoring and evaluation of performance. However, it may not suit complex or variable processes due to its reliance on stable and predictable demand and capacity. Additionally, it may not work well with high-mix or low-volume products as it may result in too many kanban cards and boards. Furthermore, some employees or managers may resist or misunderstand it as it may challenge their existing habits or assumptions. Finally, it may need to be integrated with other tools and methods such as lean, agile, or six sigma to achieve optimal results.

5 How to implement kanban?

Implementing kanban in manufacturing operations is not a simple endeavor. It requires a well-defined vision, an effective plan, and a step-by-step approach. To start, you must define the customer value and value stream, which are the products or services that the customer wants and the steps and resources needed to deliver them. You also need to map the current state of the production process, which means identifying activities, flows, and wastes that exist in the system. After that, you can identify improvement opportunities and the future state of the production process, such as goals, metrics, and changes you want to achieve. Then design and test a kanban system with cards, boards, bins, and rules to control the workflow. Finally, you must implement and monitor the system with actions, feedback, and adjustments to ensure its effectiveness and efficiency. Don't forget to review and improve the kanban system through audits, reviews, and improvements for sustainability.

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?