The Kanban Playbook

Table of contents

1. How to Use This Playbook
2. Introduction
   1. 8 Wastes
   2. Lean Metrics
      1. Productivity
      2. Quality
      3. Inventory
      4. Floor Space
      5. Travel Distance
      6. Throughput Time
3. Chapter 1 - Cycle Counting and Baseline
   1. Introduction
   2. Creating a Kanban Sizing Report
   3. Cycle Counting, Part Identification, Vendors, and On-Hand Inventory
   4. Identification of New Inventory Quantities
   5. Calculating New On-Hand Costs
      1. Creating a Kanban Sizing Report
4. Chapter 2 - 5S and New Maximum Quantities
   1. Sorting
   2. Location Designations
5. Chapter 3 - Kanban Cards
   1. Introduction
   2. Benefits of Kanban
   3. Kanban Defined
   4. Creating a Kanban Card System
   5. Break Down Items into Categories
   6. Establish Maximum Quantity: Usage Is Key
   7. Pros and Cons of Higher Maximum Quantities
   8. Pros and Cons of Lower Maximum Quantities
   9. Maximum Quantity Examples
   10. Establish the Minimum Quantity
   11. Establish Reorder Signal or Quantity
   12. Reorder Signal
   13. Kanban System for Supplies
   14. Supplies Are Delivered and Card Returned
   15. Maintenance Kanban Cards
6. Chapter 4 - Two-Bin Systems and Material Handling
   1. Two-Bin Systems
   2. Material Handling
      1. Communication Lights
      2. Kanban Card or Bin Drop Point
7. Chapter 5 - In-Process Kanban
   1. What Is a Pull System?
      1. External and Internal Customers
      2. Process Based (Push)
      3. In-Process Kanban (Pull)
   2. Pull System from Assembly to Paint
   3. Items Have Location on Rack
   4. Information and Signal
   5. How It Works
   6. Welding into Powder Coating
   7. IPK into Powder Coating Department
   8. Writable In-Process Kanban (IPK)
      1. Saw Operation
8. Conclusion
9. Definition of Terms
10. About the Author