KanBan in Manufacturing Can Eliminate Bottlenecks and Maximize Capacity

Are you looking for ways to identify and stop bottlenecks and waste in your facility?

Sure. Who isn’t looking to optimize operations to achieve maximum results with minimal investment? For that reason, many manufacturing facilities and machine shops alike are starting to look to lean manufacturing techniques to help them get there.

Kanban systems are one such method that offer production teams the support they need to get the most out of their operational processes. Following the design of pull systems and just-in-time inventory plans, Kanban cards are small cards with important information related to specific operational processes. These cards can include information about materials and part descriptions, identifying bar codes, routing information, lead time, supplier information, order date, due date, responsible parties and more.

Kanban boards are ideal for controlling production and making operational processes visible when used as part of a lean manufacturing program. Kanbans are best described as visual markers that highlight each step of the manufacturing process. Kanbans not only helps to visualize the workflow process, but also the actual work that passes through the process. By increasing the visibility of the work to be done, over time you begin to eliminate wasted labor, inventory and time.

Related: 5 Ways to Reduce Scrap in Your Metal Cutting Operations

7 Surprising Ways Kanban Can Support Your Manufacturing Goals

1. Measure and manage workflow
   Kanbans allow production teams to have both a high-level view of workload, as well as more detailed information regarding individual tasks and priorities. Kanban systems for manufacturing can also help measure team members’ progress through each stage of the workflow.
   
   
2. Communicate more effectively
   The use of a Kanban board in your facility ensures clear and accurate communication of goals, policies and expectations without confusion. Every affected employee knows exactly what is required at every stage of the operation.
   
   
3. Limit Work in Progress (WIP)
   With an effective Kanban system in place, it’s easier to visualize workflow and backlogs at various points in time and concentrate on completing existing work before taking on new work. This offers added insight into current workload to determine if work needs to be cut back or if you have capacity to add more.
   
   
4. Improve customer satisfaction
   Using Kanban to optimize your production flows, your company can complete more work on time and in budget. Not only does this lead to happy customers, but also loyal customers who are more likely to act as evangelists on your behalf.
   
   
5. Reduce worker stress
   Individual workers, production teams and management alike experience reduced stress with the successful implementation of Kanban in their facility. Kanban offers enhanced visibility into operations and helps managers understand conflicting priorities and create solutions that eliminate bottlenecks. Workers can now focus on what they do best, rather than what is piling up ahead.
   
   
6. Improve safety and compliance
   Kanban in manufacturing not only helps to reduce production costs and waste, but can help improve safety. A smooth workflow guided by clear standard operating procedures (SOP) can eliminate bad habits and faulty material and equipment, resulting in fewer accidents and more consistency in safety programs throughout the facility.
   
   
7. Improve collaboratively and continuously
   When all parts of the process are understood by all affected employees, it’s easier to spot potential problem areas and brainstorm solutions collectively. Plus, all stakeholders have improved visibility with a clear and consistent view of the workflow.

Related from Medium: Learn more about various types of Kanban cards here.

It’s no secret that lean manufacturing methods have been key to the success of many small and mid-size manufacturing facilities. When Kanban is used with other lean manufacturing best practices, managers have experienced lower overhead and inventory costs, improved reporting, standardized production goals, better teamwork and increased accuracy.

We’re always on the lookout for ways you can improve operations and increase your profitability. From cutting tools, abrasives and cutting fluid to safety and MRO supplies, we are your full line distributor. If you have questions on how M&M Sales & Equipment can help you, please call one of our four Texas locations.