Tiếng Việt
You may not have heard of the term “kanban,” but you’ve probably applied this organizational principle without even knowing. The simple definition is using visual signals to control the flow of materials and production to maintain inventory at optimal levels. For example, when the last cereal box is empty, you know you need to buy more to have breakfast for the coming days. This principle can be applied on a larger scale in manufacturing environments.
Origin
Kanban originates from Toyota in Japan in the 1940s-1950s Leader Taiichi Ohno studied how goods were displayed in American supermarkets, where shelves were always stocked but not overstocked. He realized this principle could be applied to production by using kanban cards to control manufacturing based on actual customer demand.
Incredible Benefits
The kanban system helps reduce excess inventory, saving storage costs and space. The biggest benefit is preventing overproduction – one of the major wastes according to Lean principles.
Furthermore, kanban:
» Improves the flow of materials and goods, reducing bottlenecks
» Makes the production process more visual and understandable
» Helps businesses flexibly respond to fluctuations in demand
» Empowers workers to control production autonomously
Common Types of Kanban Systems
- Two-card system: Uses two types of cards – production and withdrawal, circulating between warehouses, production lines, and delivery areas.
- Two-bin system: Uses two identical bins placed side by side. The empty front bin is replaced by the full bin from behind, and the empty bin is taken away for replenishment.
- Three-bin system: One bin is at the factory, one at the warehouse, and one at the supplier. Empty bins are rotated between points for material replenishment.
- E-kanban (electronic kanban): Instead of paper cards, it uses barcodes and technology to scan and generate electronic requests.
Kanban Board – Visual Tool Inside and Outside Production
A kanban board with columns “To-Do“, “Doing“, “Done” allows visually tracking work progress. Task cards move through corresponding columns. This board is suitable not only for manufacturing but also for office environments, helping control the amount of work in progress.
Successful Deployment of Kanban System
Before implementation, consider its suitability to your operations. If there’s a lot of demand variability or unstable material deliveries, implementing kanban might be more challenging.
The first step is organizing the workspace by applying 5S. A tidy work environment will ensure visual signals like kanban cards are not overlooked.
Next, identify the suitable system type and design details: signal type, flow of movement, information on kanban cards, etc. Gather input from employees for easy acceptance of the system. Calculate the necessary number of cards/bins for continuous material flow. After deployment, adjust and update the process continuously to fit.
Simple yet Effective
Although kanban originates from a simple idea, it’s an effective tool for optimizing processes in organizations large and small, not only in manufacturing but also in offices and storage facilities. Transitioning to kanban requires change but brings many benefits to businesses, employees, and customers.
Summary translated by Athena I&E
Reference: “The Art of Kanban” – Creative Safety Supply
