Kanban — Visual Workflow Control
Design a pull-based production system that eliminates overproduction, controls inventory, and creates smooth, demand-driven flow across your entire value chain.
SYSTEM
Control Flow. Eliminate Waste.
Kanban (看板) — ‘visual board’ — is a production scheduling system that originated in the Toyota Production System as the operational mechanism for Just-In-Time (JIT) manufacturing. By using visual signals (cards, bins, or electronic alerts) to trigger production and replenishment only when needed, Kanban eliminates overproduction — one of the most costly wastes in any manufacturing or service operation. At Q’mArk Group, we design and implement Kanban systems tailored to your specific production environment and supply chain structure.
Whether you require a simple two-bin replenishment system for consumables, a production Kanban loop between manufacturing cells, or a full supplier Kanban integrated with your ERP system, our industrial engineering experts analyse your demand patterns, lead times, and process variability to calculate optimal Kanban quantities and design a system that delivers measurable improvements in inventory turns, on-time delivery, and cash flow.
Kanban System Design
We analyse your production flow, demand patterns, and replenishment lead times to design the optimal Kanban system — production Kanban, withdrawal Kanban, supplier Kanban, or two-bin — with calculated card quantities based on actual data.
WIP Limit Setting & Flow Control
We establish Work-In-Progress limits at each process stage to prevent overloading, surface bottlenecks quickly, and create a smooth, predictable production flow — reducing both lead time and production variability.
Visual Management & Kanban Boards
We design and install physical Kanban boards, bin systems, signal cards, and floor markings that make the status of production flow instantly visible to all team members and supervisors at a glance.
Supplier Kanban & ERP Integration
We extend Kanban discipline to your supply chain — connecting your replenishment signals to supplier schedules and, where applicable, integrating with your MRP/ERP system for seamless, data-driven pull-based procurement.
Our Engagement Roadmap
Value Stream Mapping & Flow Analysis
We map your current production value stream to identify overproduction points, inventory accumulation, and push-based scheduling — quantifying the opportunity for a Kanban-based pull system.
Kanban Calculation & System Design
Using demand data, replenishment lead times, and safety stock requirements, we calculate optimal Kanban quantities and design the complete system architecture — cards, bins, boards, and signal rules.
Pilot Implementation & Training
We pilot the Kanban system on a selected production line or area, training your team on Kanban rules, discipline, and board management — validating system performance before full rollout.
Full Deployment & Continuous Improvement
We support the full-scale deployment of Kanban across your operations, establish monitoring metrics, and provide ongoing coaching to refine WIP limits and system rules as demand patterns evolve.