How do you create a kanban system?

2 Define your kanban rules

Next, you need to define the rules and parameters that will govern your kanban system. These include the type and number of kanban cards or signals you will use, the size and location of the kanban bins or containers, the trigger points and replenishment methods for each kanban, and the roles and responsibilities of the team members involved. You should also establish the metrics and indicators that will help you monitor and evaluate the performance of your kanban system.

3 Design your kanban board

A kanban board is a visual display that shows the status and progress of the tasks or items in your kanban system. You can use a physical board with sticky notes, magnets, or cards, or a digital board with software or apps. You should design your kanban board according to your process steps, kanban rules, and team preferences. A typical kanban board has three columns: to do, doing, and done, but you can customize it to suit your needs.

4 Implement your kanban system

Once you have designed your kanban board, you can start implementing your kanban system. You should communicate the purpose and benefits of the kanban system to your team and stakeholders, and provide them with the necessary training and support. You should also ensure that the kanban cards or signals are clear, visible, and accessible, and that the kanban bins or containers are properly labeled and organized. You should follow the pull principle, which means that you only produce or move what is requested by the downstream process or customer.

5 Monitor and adjust your kanban system

After you implement your kanban system, you should monitor and adjust it regularly to ensure that it is working effectively and efficiently. You should track and review the metrics and indicators that you defined in step two, such as cycle time, lead time, throughput, inventory turnover, quality rate, and customer satisfaction. You should also collect feedback from your team and customers, and identify any issues or challenges that arise. You should use tools such as PDCA (plan-do-check-act) or Kaizen (continuous improvement) to solve problems and make improvements.

6 Expand and optimize your kanban system

Finally, you can expand and optimize your kanban system to cover more processes, products, or services, and to achieve higher levels of performance and quality. You can use tools such as 5S (sort, set, shine, standardize, sustain) or Poka-Yoke (error-proofing) to eliminate waste and defects, and to create a more organized and safe work environment. You can also use tools such as SMED (single-minute exchange of die) or Heijunka (leveling) to reduce setup time and balance the workload.