Kanban is a visual system that helps you manage the flow of work in your Lean Manufacturing team. It helps you reduce waste, improve quality, and deliver value to your customers faster. But how can you ensure your team is using kanban effectively? Here are some tips to follow.
One of the key principles of kanban is to limit the amount of work in progress (WIP) at each stage of the process. This prevents bottlenecks, overproduction, and inventory buildup. You need to set clear rules and limits for your team on how many tasks they can work on at any given time, and how they can move them from one column to another on the kanban board. For example, you can use a pull system, where the team only starts a new task when there is an empty slot in the next column, or a push system, where the team moves a task to the next column when it is done, regardless of the availability of the next stage.
In my experience training, WIP limits, and clear policies are important. But more importantly by making it very visual and physical with physical cards, visual signals, regular stand-ups/reviews in person. To top it up add gamification and make it fun and competitive across the team and multiple teams.
Another key principle of kanban is to monitor and measure the flow of work through the system. You need to track metrics such as cycle time, lead time, throughput, and quality. These metrics help you identify problems, inefficiencies, and opportunities for improvement in your process. You can use tools such as cumulative flow diagrams, control charts, and histograms to visualize and analyze the data. You can also use feedback loops, such as daily stand-up meetings, retrospectives, and customer reviews, to share information and insights with your team and stakeholders.
Kanban is a method which helps us in managing & controlling the production flow each process, this structured method provides multiple tools and techniques to check, monitor & control the work flow in each process, sub-process. It is a pull based system which means it is controlled by customer demand. Monitor the workflow using Kanban: Identification of WIP: Analysing the material flow: Implementing the techniques like JIT: Monitoring the implementation status:
The final key principle of kanban is to implement continuous improvement. You need to constantly look for ways to optimize your process, eliminate waste, and increase value. You can use techniques such as root cause analysis, 5 whys, and PDCA (plan-do-check-act) cycles to identify and solve problems. You can also use experiments, such as A/B testing, hypothesis testing, and pilot projects, to test and validate new ideas. You can also use kaizen events, such as workshops, brainstorming sessions, and gemba walks, to involve your team and other stakeholders in the improvement process.
To use kanban effectively, you need to train and empower your team. You need to make sure your team understands the principles and practices of kanban, and how they align with the goals and values of Lean Manufacturing. You need to provide them with the necessary skills, tools, and resources to perform their tasks efficiently and effectively. You also need to encourage them to take ownership, responsibility, and initiative for their work. You need to foster a culture of collaboration, communication, and learning within your team and across the organization.
Finally, you need to review and update your kanban system regularly. You need to check if your kanban board reflects the current reality of your process, and if it meets the changing needs and expectations of your customers. You need to adjust your rules and limits, your metrics and feedback loops, and your improvement techniques as needed. You need to keep your kanban system simple, flexible, and adaptable to the dynamic environment of Lean Manufacturing.
1. Do Gemba walks for production plant & warehouse to check for effective implementation of Kanban system 3. Do internal audit for supply chain dept. 4. Check that there no stoppage of production due to shortage of raw materials/ starting material/ packaging material