How Kanban worksLet’s imagine the following scenario. You own three large doughnut shops, and a factory that supplies your shops with doughnuts. In the last five years demand for doughnuts has spiked. At your flagship store, you stock 100 different varieties of doughnut. Your team of 20 work flat-out serving your customers 20,000 doughnuts each day. However, you face the constant problem of waste. You know your top selling doughnuts. But the Glazed, the Boston Cream Glazed, the Chocolate, the Raspberry-jelly filled and the strawberry doughnut sell out at different times and in different seasons. You’ve learned never to take anything for granted. Even your best selling doughnuts occasionally have a bad day. Last Tuesday for example, there were 509 unsold Boston Creams, and 195 strawberry doughnuts still on the shelves. While the business’s profit margins are increasing year-on-year, you realise that your company would benefit greatly from a employing a Lean manufacturing tool. You decide to opt for Kanban. Kanban is a Lean Manufacturing Tool for producing items in a highly efficient manner. It’s a scheduling system which tell you what to produce, when to produce it, and how much to produce. Kanban is also the Japanese word for sign, and Kanbans are signs used to schedule and track production from inventory, to manufacturing and delivery.
Three stages of KanbanThe simplest Kanban systems employ three stages, which are as follows: - To do - Doing - Done
Kanbans explainedSo in this case: - Your TO DO Kanbans are inventory supply. - Your DOING Kanbans are making the ten different types of doughnuts, listed below.
- Boston Cream Glazed doughnut
- Chocolate Glazed doughnut
- Raspberry jelly filled doughnut
- Strawberry doughnut
- Jam doughnut
- Sour Cream Glazed doughnut
- Cinnamon doughnut
- Maple Glazed doughnut
- Custard filled doughnut
- Apple Brown Sugar doughnut- Your DONE Kanbans are packaging and transporting the doughnuts to market.