Kanban

Introduction: Kanban

Kanban is a Lean tool used to manage work visually with cards, boards, or digital systems. It signals when new work should start, based on actual demand and available capacity, helping teams prevent overproduction and reduce bottlenecks. Kanban makes workflows visible, enabling better planning and smoother flow.

Background

The term Kanban, meaning “signboard” in Japanese, was developed at Toyota in the 1940s as part of the Pull System within the Toyota Production System (TPS). Originally applied to production control using physical cards, Kanban became a key mechanism for Just-in-Time manufacturing. Over time, it has been adapted beyond factories to fields such as software development, healthcare, and service management.

Key Elements / Features

• Visual cards: Represent tasks, products, or items in progress.
• Workflow stages: Boards with columns show steps such as To Do, In Progress, Done.
• Work-in-progress (WIP) limits: Restrict the number of items in progress to avoid overload.
• Pull principle: Work is only started when there is capacity downstream.
• Continuous improvement: Teams regularly review the board and refine processes.

Applications / Examples

• Manufacturing: Using Kanban cards to trigger production or material replenishment.
• Software development: Agile teams using digital Kanban boards (e.g., Jira, Trello) to track tasks.
• Healthcare: Organising patient flow or managing medical supply chains.
• Office work: Visualising approval steps, document workflows, or project tasks.

Relevance / Impact

Kanban increases transparency, reduces waste, and balances workloads across teams. It provides a simple yet powerful way to visualise work, highlight bottlenecks, and ensure steady, demand-driven flow. By limiting WIP and encouraging pull, Kanban supports Lean principles and continuous improvement in any environment.

See also

• Pull System
• Just-in-Time (JIT)
• Lean
• Kanban Card