How can you simplify complex Kanban systems?

1 What is Kanban?

Kanban is a Japanese word that means "signboard" or "card". It is a visual system that uses cards, bins, or other signals to indicate the status and demand of work items in a production process. The main idea of Kanban is to limit the amount of work in progress (WIP) and to pull work from the previous stage only when there is capacity and demand. This way, Kanban helps to reduce waste, improve quality, and balance the workload.

2 Why is Kanban complex?

Kanban may appear basic on the surface, however it can become intricate when managing multiple products, variants, customers, suppliers, and processes. Factors that can escalate the complexity of Kanban include the number and size of Kanban cards or bins, the frequency and method of replenishment, the variability and uncertainty of demand and supply, the dependencies and interactions between different stages and teams, the rules and policies for prioritizing and allocating work, as well as the metrics and feedback mechanisms for monitoring and improving performance.

3 How to simplify Kanban design?

To simplify complex Kanban systems, design them with clarity and simplicity in mind. Standard sizes and colors for Kanban cards or bins make them easy to identify and handle. Labels and symbols should be simple and clear, and each card or bin should have a single point of contact to avoid confusion and duplication. Establish a common replenishment cycle for all cards or bins to synchronize the flow and reduce variation. Additionally, use a single source of truth for demand and supply data to ensure accuracy and consistency. Lastly, use a modular and scalable approach to accommodate changes and growth.

4 How to simplify Kanban operation?

To simplify complex Kanban systems, it is important to operate them with discipline and flexibility. This can be achieved by following the pull principle and respecting the WIP limits to avoid overproduction and congestion. Communication and collaboration with upstream and downstream partners can help align expectations and resolve issues. Additionally, it can be beneficial to adjust the Kanban parameters and rules based on the actual conditions and feedback. Empowering frontline workers to make decisions and take actions based on the Kanban signals is also recommended. Finally, it is essential to continuously monitor and improve the Kanban system using data and visual tools.

5 How to avoid Kanban pitfalls?

Even with a simple and well-designed Kanban system, there are some pitfalls that can undermine its effectiveness and efficiency. To ensure success, it's important to avoid treating Kanban as a one-size-fits-all solution and to involve and train those who will use it. Furthermore, it is essential to understand the root causes of problems and the principles and philosophy behind Kanban rather than relying on it as a quick fix or a band-aid. Additionally, one should not become complacent or stagnant with the current Kanban system but instead seek opportunities for improvement and innovation.