LEAN Toolboxby Availix · Interactive LEAN tools

Purpose and method

Size and manage a visual pull system according to demand, replenishment time, container quantity and safety factor.

When to use it

Use Kanban for repeatable consumption where inventory should be replenished by actual use instead of forecast pushing.

Core principle

Kanban authorises replenishment; it does not compensate for unlimited instability. The loop must have a clear supplier, customer, replenishment trigger and maximum inventory.

What the interactive module provides

  • Kanban quantity calculation
  • Card data
  • Pull-loop parameters
  • recommended card/container count, maximum loop inventory and documented operating assumptions
Professional verification: The module supports learning, analysis and documentation. Verify results against actual process conditions, internal standards, safety requirements and competent professional judgement before implementation.
01

Recommended workflow

Size a pull loop from demand, replenishment time, container quantity and justified safety factor, then define the signal and operating rules.

  1. 1

    Define one supplier-customer replenishment loop

  2. 2

    Measure demand rate and full replenishment lead time

  3. 3

    Choose standard container quantity and signal

  4. 4

    Calculate and round the initial card count

  5. 5

    Pilot, monitor stockouts and reduce causes before cards

02

Practical example

Demand is 240 pieces per shift, replenishment takes 90 minutes, containers hold 20 pieces and the justified safety factor is 15%. The calculation determines the card count and exposes the effect of long replenishment time.

Calculation or verification principle

Kanban quantity = demand rate × replenishment lead time × (1 + safety factor) ÷ container quantity, rounded up to a whole signal.

Required inputs → Expected outputs

Required inputs
demand rate, replenishment lead time, container quantity, safety factor, loop boundaries and signal type
Expected outputs
recommended card/container count, maximum loop inventory and documented operating assumptions
03

Common mistakes to avoid

×

Using average lead time while ignoring frequent delays

×

Adding arbitrary safety stock instead of reducing instability

×

Allowing production without a valid signal

×

Changing container size without recalculating the loop

04

Frequently asked questions

What data do I need to use this tool?

Prepare demand rate, replenishment lead time, container quantity, safety factor, loop boundaries and signal type.

What result does the module produce?

The module produces recommended card/container count, maximum loop inventory and documented operating assumptions.

Can I implement the result without further review?

No. Treat the output as a structured engineering and improvement aid. Verify source data, assumptions, safety, quality, legal requirements and local process conditions with competent responsible people before implementation.

05

Related LEAN tools

Just-in-Time Flow AssessmentAssess whether flow, takt, pull, levelling, quality and replenishment stability are ready to support lower inventory without increasing delivery risk.Value Stream Mapping (VSM)Combine material flow, information flow, inventory, process data and timeline to understand end-to-end lead time and design a realistic future state.Takt Time CalculatorConvert customer demand and net available production time into the required completion rhythm, then compare takt with cycle time and capacity.5S Workplace OrganisationBuild a visual workplace standard, evaluate every 5S step and turn findings into a practical action plan.
LEAN Toolbox

Kanban Pull-System Sizing
Size a pull loop from demand, replenishment time, container quantity and justified safety factor, then define the signal and operating rules.

Open interactive tool →