{"id":44528,"date":"2023-03-23T14:39:37","date_gmt":"2023-03-23T18:39:37","guid":{"rendered":"https:\/\/www.flexpipeinc.com\/?p=44528"},"modified":"2025-09-16T16:02:35","modified_gmt":"2025-09-16T20:02:35","slug":"how-ekanbans-optimize-your-material-replenishment-process","status":"publish","type":"post","link":"https:\/\/www.flexpipeinc.com\/us_en\/how-ekanbans-optimize-your-material-replenishment-process\/","title":{"rendered":"How Ekanbans Optimize Your Material Replenishment Process"},"content":{"rendered":"\n

When companies think about Kanban, the image of a Kanban board and Kanban cue cards often come to mind. This simple lean manufacturing scheduling system summarizes workflow on a board, showing individual steps required to complete a given project, work, or operation.<\/p>\n\n\n\n

The Kanban board<\/a> is the repository for the Kanban cards<\/a>. The board outlines a given manufacturing process or defines each stage of a product or project\u2019s step-by-step process. The cards are then placed on the board outlining what tasks need completion.<\/p>\n\n\n\n

\"Aerospace
Aerospace producibility board \u2013 Source: planview.com<\/figcaption><\/figure>\n\n\n\n

Cards define what work has been requested, what is currently being worked on, and what work is completed. They represent what remains to be done before moving to the next process step. These cards are also used to outline different ideas and approaches to help move the process along.<\/p>\n\n\n

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\"Kanban<\/figure>\n<\/div>\n\n\n

The Origins of Kanban<\/strong><\/h2>\n\n\n\n

In its simplest form, Kanban is a method of tracking manufacturing workflow or a project\u2019s history. It is a highly effective scheduling method for lean manufacturing, helping to define how much inventory is needed to support current workloads.<\/p>\n\n\n\n

Its origins can be traced back to Taiichi Ohno, who \u2013 along with Sakichi Toyoda and his son Kiichiro Toyoda \u2013 are responsible for developing the Toyota Production System (TPS) and its many lean and continuous improvement<\/a> methodologies.<\/p>\n\n\n\n

\"Toyota
Toyota Production System Kanban board. Source: toyota-global.com<\/a><\/figcaption><\/figure>\n\n\n\n

Like many lean methodologies<\/a> emerging from Toyota, Kanban relies upon simple visual cues. The word Kanban is Japanese and literally translates to \u201ccard you can see.\u201d It is considered the core tool for managing Just-in-Time (JIT) manufacturing, another lean pillar of TPS. Toyota introduced JIT and Kanban during the 1940s.<\/p>\n\n\n\n

JIT is considered a pull system where customer demand is the driving force behind manufacturing. This customer demand essentially \u201cpulls\u201d products to be made, unlike the North American manufacturing processes at that time that relied on pushing products to the market to spur customers to buy those products.  <\/p>\n\n\n\n

Kanban is seen as an innovation in that it follows similar TPS guidelines; minimizing costs, eliminating waste<\/a>, and shortening lead times is the best way to add value for customers.<\/p>\n\n\n\n

Kanban in Today\u2019s Business Environment<\/strong><\/h2>\n\n\n\n

Companies still use Kanban boards and even post-it notes as a convenient replacement for the Kanban cards. Other companies have moved away from this manual process. They have instead adopted digital, SaaS, cloud-based, and mobile-optimized software solutions that provide granular data and up-to-the-instant feedback on workflow and production volumes.<\/p>\n\n\n\n

This adoption of real-time platforms has given rise to multiple Ekanban (electronic Kanban) systems that are quickly replacing the visual cue systems of the past. These systems provide invaluable details to line-side operators, managers, project managers, employees, and technicians in manufacturing environments.<\/p>\n\n\n\n

Having a system that tracks production data and a project\u2019s progress in real-time is invaluable. It shortens the time it takes to make critical decisions and course corrections. It identifies areas of concern and provides pinpoint accuracy on issues that impact workflow. It allows companies to determine when inventory needs replenishment to keep up with demand<\/a>.<\/p>\n\n\n\n

Ekanban systems can be accessed from any laptop, mobile phone, or desktop with an internet or Wifi connection. This means designated employees can easily track production throughput no matter where or when they work. Employees no longer have to view the Kanban board to get a breakdown of production throughput, and nobody has to spend any time updating that board. Instead, everyone merely accesses the information on their own.<\/p>\n\n\n\n

Simple, Scalable, and Modular EKanban Systems<\/strong><\/h2>\n\n\n\n

One of the drawbacks for manufacturers is the cost of fully implementing an Ekanban system<\/a> alongside its existing software, like Enterprise Resource Planning (ERP), Material Requirements Planning (MPR), and other production or inventory management systems. However, like Flexpipe\u2019s tube and joint system, there are modular and scalable solutions that allow you to gradually introduce EKanban without breaking the bank.<\/p>\n\n\n\n

Steute Technology\u2019s NEXY Digital Shop Floor Solution<\/a> is one of these modular and scalable systems. Rob Hargis of Steute USA outlines some simple ways the company\u2019s Ekanban system works.<\/p>\n\n\n\n

Watch Ian Johnson from Flexpipe and Rob Hargis<\/a> of Steute USA<\/a> outlining some simple ways the NEXY Digital Shop Floor<\/a> Ekanban\u2019s system is working.<\/p>\n\n\n\n

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