1st Edition

The Kanban Playbook
A Step-by-Step Guideline for the Lean Practitioner

ISBN 9781498741750
Published September 11, 2015 by Productivity Press
75 Pages 65 Color Illustrations

USD $42.95

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Book Description

This book is intented for Lean practitioners and facilitators looking for a training tool and guideline that can be used in the work area while improvements are being made. It provides the most visible and detailed approach to Kanban implementation, so that they can see results in a short period.

Table of Contents

Cycle Counting and Baseline
Creating a Kanban Sizing Report
Cycle Counting, Part Identification, Vendors, and On-Hand Inventory
Identification of New Inventory Quantities
Calculating New On-Hand Costs
Creating a Kanban Sizing Report

5S and New Maximum Quantities

Location Designations

Kanban Cards

Benefits of Kanban
Kanban Defined
Creating a Kanban Card System
Break Down Items into Categories
Establish Maximum Quantity: Usage Is Key
Pros and Cons of Higher Maximum Quantities
Pros and Cons of Lower Maximum Quantities
Maximum Quantity Examples
Establish the Minimum Quantity
Establish Reorder Signal or Quantity
Reorder Signal
Kanban System for Supplies
Supplies Are Delivered and Card Returned
Maintenance Kanban Cards

Two-Bin Systems and Material Handling

Two-Bin Systems
Material Handling
Communication Lights
Kanban Card or Bin Drop Point

In-Process Kanban

What Is a Pull System?
External and Internal Customers
Process Based (Push)
In-Process Kanban (Pull)
Pull System from Assembly to Paint
Items Have Location on Rack
Information and Signal
How It Works
Welding into Powder Coating
IPK into Powder Coating Department
Writable In-Process Kanban (IPK)
Saw Operation


Definition of Terms


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Chris Ortiz is the founder and president of Kaizen Assembly, a Lean manufacturing training and implementation firm in Bellingham, Washington. Kaizen Assembly’s clients include industry leaders in aerospace, composites, processing, automotive, rope-manufacturing, restoration equipment, food processing, and fish-processing industries.

Chris has been featured on CNN Headline News on the show "Inside Business with Fred Thompson." He is the author of six books on Lean manufacturing. Chris is a frequent presenter and keynote speaker at conferences around North America. He has been interviewed on KGMI radio and the American Innovator and has written numerous articles on Lean manufacturing and business improvement for various regional and national publications.

Chris is considered to be an expert in the field in Lean manufacturing implementation and has over 15 years of experience in his field of expertise.

Watch Fred Thompson talk about Kaizen Assembly and Chris Ortiz on "Inside Business with Fred Thompson" at: