Always turn kanban cards in after lunches, breaks, and between shifts to get up to date scheduling every two hours.
Have a common drop off location for cards to be dropped off (Example: break room, restroom or production office). Operators on the way back from break or restroom will look at kanban drop off to see if any parts are pulled from their processes. If there are cards the operator will return the cards to their work station and place them on the kanban board.
Never run over the kanban card amount and never substitute paper notes for kanban cards. If you must run extra parts get overrun cards from the scheduling department. It’s always best to run the specified kanban amount.
Never run machines with set-up times earlier than when the cards are fully up to the green on the kanban board. This would create unnecessary set-ups. If no cards are up to the GREEN don’t run the machine.
Nothing is made or moved without a kanban card.
Always fill containers to specified quantity on kanban card. If you have a partial container generated at the end of a run, use a partial tag to identify the container and store it away from the primary location. When that part is set-up on the next run then finish filling the container.
Always define kanban cards with a color scheme. (Example: W.I.P. “Green”, Finished Goods “Yellow”, Overrun Cards “Orange”, etc...
Always start out slow when implementing kanban. Do one machine and then audit that machine for at least two weeks to make sure you have the discipline in the system. Then implement another machine. As you get more machines done the faster the process will go, because people will see the system work and want it on their machines.
Train Everybody!!!! This is very important.
Always start the kanban system simple, then fine tune the system later. If you start a difficult kanban system, it will fail.
Pass scheduling responsibility to the Operators. This gives process ownership to the people operating the equipment or work center. They will get a feel for the schedule and smooth out the flow. Scheduling personnel should only step in when a designated quantity of parts are in the red.
Schedule overtime based on kanban cards in the red zone.
Only quality parts are sent to the subsequent processes.
Kanban cards are not to be left on products in the hold area.
Establish a primary location for all parts.
Place a kanban card on all parts in stock when setting up the kanban board on a machine. This will tell you where you are at with the schedule on the Kanban board.
Kanban Process Flow