Comprehensive Definition
Kanban (a Japanese term meaning "card" or "visual signal") is a workflow management method that allows controlling production and material replenishment visually and in real time. It is based on a "Pull" system, where consuming an item automatically triggers a replenishment order, avoiding excess stock and ensuring materials are available only when needed.
How Does Kanban Work in the Warehouse?
Traditionally, Kanban used physical cards on boards, but in Logistics 4.0, the process has been digitized through e-Kanban integrated into the WMS:
Replenishment Signal
When a picking operator removes the last box from a "Pick Face" location, the system generates a visual alert (or an automatic mission) for stock to be replenished from the reserve zone.
Two-Bin System
A common method for small parts (such as screws or electronic components). When the first bin empties, the second is used while the first is sent for replenishment.
Virtual Cards in WMS
The software monitors stock levels and, upon reaching the "Reorder Point", visually signals the purchasing manager or supplier of the need for a new shipment.
Implementation Advantages
Reduction of Idle Stock
By replenishing only what has been consumed, companies can free up tied-up capital and gain useful warehouse space.
Response Agility
Enables quick reactions to demand peaks without the need for complex and often inaccurate sales forecasts.
Intuitive Visual Management
Reduces operator stress, as they know exactly what needs to be done just by looking at control screens or shelves.
Production Synchronization
In manufacturing, Kanban is essential for feeding assembly lines without interruptions, ensuring a continuous flow of materials.
Difference Between Kanban and JIT
Often confused, Just-in-Time (JIT) is the philosophy/end goal, while Kanban is the practical, visual tool used to achieve that goal.