This is part 6 of a 6-part step-by-step series on kanban deployment. This article covers specifics of properly deploying kanban cards for inventory items with Break-a-Bin (BaB) replenishment triggering.
Break-a-Bin (BaB) Cards
Deploying the cards for Break-a-Bin (BaB) systems is far easier than it is for Empty-a-Bin (EaB) systems. The main reason for this is that one BaB card always represents a full Kanban Order Quantity (KOQ). For example, if the KOQ is four boxes of 50 items, then every single BaB card will represent 200 items.
To deploy BaB cards, start by sorting your on-hand items into separate quantities equal to the KOQ. Next, pair a kanban card with each full KOQ. If any items remain in an amount less than a full KOQ, these leftover items will not be paired with a card. Finally, just as with EaB, all unassigned BaB cards are scanned and placed on the kanban card to await arrival of the orders they triggered.
Deploying BaB Kanban Cards with Excess Inventory
As with EaB, excess inventory must be given special attention including but not limited to kanban audits, temporary procedures or special exceptions.
For example, typically, BaB cards trigger new orders every time a full KOQ-sized bin of items is opened or “broken”. However, there is an important exception. When you have excess inventory (such as is often the case when first deploying Kanban), a new order should NOT be processed normally for replenishment by the supplier. Instead, items should be replenished from excess inventory until […]