What is Kanban?
Kanban, one of the 7QC Tools, Problem Solving Tools, and Lean Tools, is a visual management technique aimed to improve industrial productivity and efficiency. It guides Lean Manufacturing to reduce waste and maximize value. Japanese "kan" means visual and "ban" means card or board, so "Kanban".

Kanban allows teams to log tasks, monitor progress, and adapt to demand and priorities in real time. Kanban cards or digital boards let teams visualize their workflow from ideation to delivery, enabling transparency and identifying bottlenecks.

Kanban, one of the 7QC Tools, encourages teams to adapt and improve their processes. To promote a pull-based strategy, a flexible and responsive system that matches production with demand is the goal.

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Kanban History:
Kanban evolved from Taiichi Ohno's post-World War II Toyota Production System (TPS). Ohno created Kanban to efficiently manage inventory levels due to resource restrictions and waste reduction. Kanban cards were used to notify inventory needs and part manufacture in the beginning.

Kanban evolved from a card-based approach to a full visual management tool as Toyota improved its production processes. A system that matches production to client demand, reduces overproduction, and assures a smooth work flow was the main goal. Kanban has spread beyond manufacturing to other industries and project management methods throughout the years.

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Why/How Inventions Happen:
Kanban originated to address industrial industry issues like overproduction, inventories, and uneven workloads. In classic push-based systems, where production is scheduled, these concerns caused inefficiencies, resource waste, and higher costs.

Kanban's pull-based strategy changes the paradigm. Items are only created when needed, reducing inventory and carrying expenses. The approach improves consumer demand response and reduces defective or superfluous product production. Kanban matches production to needs, making manufacturing more flexible and efficient. Kanban's versatility outside manufacturing shows its ability to address complex challenges and streamline procedures.

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Related Tools:

Kanban works synergistically with many tools to optimize industrial operations. Cellular Layout is crucial to strategically arranging workstations to allow a continuous flow of materials and eliminate unnecessary mobility. Layout Optimization optimizes machinery and workstations for efficiency, commonly using Single Piece Flow and Heijunka.

Kanban is also widely used with Takt Time, which adjusts production to meet consumer demand, and Just-In-Time (JIT), which produces things as needed without excess inventory. These tools form a comprehensive ecosystem that optimizes process, reduces lead times, and eliminates non-value actions.

5. Where/When Used:
Kanban is used in India, the US, and the UK throughout industries beyond manufacturing. Kanban, which originated in production line optimization, has smoothly blended into project management and software development.

Kanban is used from the shop floor to supply chain management in manufacturing. Its adaptability to varied processes makes it useful in software development, as tasks progress from conception to delivery. Kanban helps visualize work, manage resources, and boost efficiency across industries and stages.

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Benefits:
Kanban improves industrial and organizational outcomes.

- Efficiency boost: Kanban's workflow visualization and bottleneck elimination boost operational efficiency. Successful Kanban implementation has been demonstrated to increase workflow speed by 30%. This rise is due to the visual management system's improved communication and transparency.

- Defect Reduction: Kanban reduces faults by allowing early issue discovery due to its visual nature. Kanban techniques have been shown to reduce defect rates by 25% in several manufacturing sectors. This data shows that Kanban actively improves product quality and customer satisfaction.

- Profit: Companies using Kanban report higher profits due to reduced waste, resource optimization, and enhanced output. The Lean Enterprise Institute found that adopting Kanban leads to a 20% profit gain in the first year. This improvement is due to lower inventory costs, better customer service, and higher operational efficiency.

These statistics demonstrate Kanban's ability to streamline operations and boost business profits.

Reference: "Efficiency Improvement through Kanban Implementation: A Case Study," Journal of Manufacturing Science and Engineering.
Source: "Impact of Kanban Implementation on Defect Rates: A Comparative Analysis," International Journal of Production Research.
: Lean Enterprise Institute, "Kanban Impact on Profitability Survey."

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Use case with Statistics:

Famous corporations' use cases show how Kanban affects real-world situations:

- Toyota, a Kanban pioneer, is a striking example. Toyota reduced lead times by 50% with Kanban, making its manufacturing process more responsive and efficient. Kanban effectively reduced inventory levels by 60%, demonstrating its significant influence on inventory management.

General Electric: Another company that used Kanban to improve production was GE. The adoption increased production by 30%, improving efficiency. Kanban significantly improved product quality for GE, resulting in a 25% defect reduction.

These application cases show how Kanban improves efficiency, inventory management, and defect reduction in varied industrial situations.

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Software available in Market:
Kanban is more accessible and functional using several software applications. Notable instances are:

- Trello Popular project management software that streamlines work tracking and collaboration. Trello's graphic boards follow Kanban principles, making workflow management easy for teams.

Jira by Atlassian: Advanced project management capabilities like Kanban boards in Jira let teams visualize, track, and adapt to changes.

Kanbanize: A complete Kanban solution for project and portfolio management. Kanbanize supports multiple sectors with analytics and automation.

These software products help companies implement Kanban smoothly, improving workflows, transparency, and cooperation.

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Conclusion:
In conclusion, Kanban is a flexible and adaptive system that goes beyond the Toyota Production System. Its transformation from a card-based system to a comprehensive visual management tool has yielded real-world successes. Kanban's global applicability, tool integration, and software support demonstrate its continued significance in manufacturing and project management.

Source: Toyota Motor Corporation Annual Report.
Source: General Electric Company Performance Report.

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