Kanban System Designer

Overview

The Kanban System Designer skill provides comprehensive capabilities for designing and implementing pull-based production control systems. It supports kanban sizing, WIP limit determination, supermarket design, and electronic kanban configuration for efficient material flow.

Capabilities

• Kanban sizing calculation
• WIP limit determination
• Supermarket design
• Signal mechanism configuration
• Pull system simulation
• Heijunka box design
• Electronic kanban (e-kanban) configuration

Used By Processes

• LEAN-004: Kanban System Design
• TOC-002: Drum-Buffer-Rope Scheduling
• CAP-002: Production Scheduling Optimization

Tools and Libraries

• Kanban software APIs
• Inventory management systems
• Simulation tools
• Visual board platforms

Usage

skill: kanban-system-designer
inputs:
  product_family: "Widget Assembly"
  demand_data:
    average_daily: 500
    peak_daily: 750
    variability: "medium"
  lead_time_data:
    replenishment_time: "4 hours"
    safety_factor: 1.5
  container_size: 50
outputs:
  - kanban_quantity_calculation
  - supermarket_layout
  - signal_card_design
  - wip_limits
  - implementation_plan

Workflow

1. Analyze Demand - Review historical demand patterns and variability
2. Calculate Kanban - Determine number of kanbans needed
3. Design Signals - Create visual or electronic signal mechanisms
4. Set WIP Limits - Establish limits for each process step
5. Configure Supermarkets - Design inventory storage points
6. Implement and Tune - Deploy system and adjust parameters

Kanban Calculation Formula

Number of Kanbans = (Daily Demand x Lead Time x Safety Factor) / Container Size

Where:
- Daily Demand = Average units consumed per day
- Lead Time = Time to replenish (in days)
- Safety Factor = Buffer for variability (typically 1.0-2.0)
- Container Size = Units per kanban container

Integration Points

• ERP/MRP systems
• Manufacturing Execution Systems
• Inventory management platforms
• Visual management displays