Production and withdrawal kanban

Production and withdrawal kanban

The two signals answer different questions. A withdrawal signal authorizes the material handler to convey a defined quantity to the consuming process. Removing that quantity from the supermarket returns a production signal, authorizing replacement. Keep item identity, quantity and destination attached to the loop. Follow one container through both actions and check that cards cannot silently multiply. The drawing should distinguish material movement from information returning upstream. This is a physical replenishment mechanism; a board that merely displays tasks does not automatically implement the same control. Investigate missing signals and quality holds before replenishing blindly.

Follow the method

1. Producing process
2. Supermarket
3. Consuming process
4. Material handler

Follow W04, C21 and P21 through one replenishment

Fictional training case: Alder Components supplies bracket B17 from a supermarket to assembly cell C2. At 09:10 the cell starts a 12-piece container and returns withdrawal card W04. Material handler Maya must collect the next container. This exercise follows one transaction, not the sizing of the whole system.

Follow the method

1. 1. Request
2. 2. Exchange
3. 3. Convey
4. 4. Replenish
5. 5. Reconcile

One request, two different permissions

Trace a container and its two authorizations, reconcile the replenishment quantity, and respond to a quality hold without inventing another signal.

Fictional training case: Alder Components supplies bracket B17 from a supermarket to assembly cell C2. At 09:10 the cell starts a 12-piece container and returns withdrawal card W04. Material handler Maya must collect the next container. This exercise follows one transaction, not the sizing of the whole system.

Role: Material handler, supported by the producing-process leader and quality owner.

Normal condition

Each eligible full container holds 12 verified B17 brackets. Item, quantity, source, destination and card identity agree. A withdrawal signal permits a move; the released production signal permits its replacement.

The gap

A supervisor suggests making three extra containers while the producer has spare time. One stock container also has uncertain quality status. Neither fact grants another production authorization.

• The example uses a simple one-card-per-container arrangement with a defined card exchange point.
• Quality status must be verified before conveyance; card count is controlled by the process owner.

1. Read the request before touching stock

   Maya matches W04 to B17, the 12-piece quantity and C2 destination. She checks that the signal is genuine and not a duplicate of an already fulfilled request.

   Why: An empty shelf or free machine is incomplete evidence of permission. Identity and transaction status prevent the wrong item or a second fulfillment.

   Evidence: W04 is outstanding and specifies exactly one container.

2. Choose a container that can move

   She selects eligible C21, verifies its item/count/status, and leaves C23 in the controlled hold location. She does not treat the hold label as a request to consume or replace that stock.

   Why: Material authorization and product suitability are separate checks. A full container is not necessarily available stock.

   Evidence: C21 has 12 verified B17 and P21; C23 remains blocked.

3. Exchange and route the signals

   At the supermarket exchange point she removes P21 for the production collection point and attaches W04 to C21 for delivery. The producer receives P21 through the defined return route.

   Why: The material moves toward C2 while the replenishment information returns upstream. Drawing both as one forward arrow hides the two permissions.

   Evidence: C21 travels with W04; one P21 enters the producer queue.

4. Make the authorized replacement

   The producing process accepts P21 for one 12-piece replacement, verifies the output and returns that replenishment with its production identification. It declines the unsolicited 36-piece request.

   Why: The example changes location and replenishes a withdrawal; it does not increase the authorized circulating quantity.

   Evidence: One production instruction for 12 pieces; no instruction for three extras.

5. Close the trace and expose the exception

   Maya records delivery to C2 and the producer records replacement completion. The leader assigns the C23 hold to quality and tracks the effect on eligible supply separately.

   Why: A reconciliation makes missing or duplicate cards visible. Hiding the hold with extra inventory would conceal the response problem.

   Evidence: W04 fulfillment and P21 completion are linked; P22 stays with C22 and P23 stays controlled with C23.

The selected container is held at the last check

Before exchange, quality changes C21 to HOLD. C22 is still verified and the same item/quantity.

Use C22 only after checking its status; return P22, not P21. Keep C21/P21 under the hold procedure and record the changed selection.

The replenishment trace must follow the container actually withdrawn. Swapping cards casually would create false stock and production records.

The revised trace names W04, C22 and P22; C21 has no delivery event.

Run a practice session

Materials

• Printed case and blank trace
• Two differently marked card types and three container tokens
• Answer held back until pairs complete practice

1. Frame the decision · 4 minutes

   What evidence would let Maya move a container?

2. Demonstrate the exchange using tokens · 7 minutes

   Which object travels downstream and which instruction returns?

3. Pairs complete practice and hold variant · 9 minutes

   Account for every card, including the copy.

4. Debrief and transfer · 5 minutes

   Which shortcut creates an unrecorded authorization?

Debrief

• Ask a learner to defend a different valid container allocation.
• If a learner counts 24 clips, identify the duplicate before correcting the arithmetic.

Draw material and information in different line styles; explain each permission aloud before opening the answer.

Transfer into the work

Owner: Material-flow owner with quality and producing-process representatives

Record: One observed container/card trace and unresolved signal log

Review: At the next route review, then across representative replenishment cycles

Evidence: Matching identity/quantity, timely return, eligible stock status and no duplicate fulfillment

Escalate lost signals, hold delays or unreliable supply; revise the approved loop through its owner rather than adding informal cards.