Kanban - AllAboutLean.com

(EN) A Critical Look at Goldratt’s Drum-Buffer-Rope Method

Oktober 11, 2025November 23, 2014 von Christoph Roser

Eliyahu Goldratt developed different methods on how to manage production systems. These methods are nowadays known as the Theory of Constraints, or TOC for short. One key method described is called Drum-Buffer-Rope, or DBM for short. Similar to Kanban or CONWIP, it aims to constrain the work in progress (WIP) in the system. There is much discussion on which method is better than the other, although the result often depends heavily on with which method the respective author earns its living. In this post I will present how Drum-Buffer-Rope works, and discuss its advantages and shortcomings.

(EN) How Many Kanbans? – Estimation Approach and Maintenance

Oktober 11, 2025Mai 18, 2014 von Christoph Roser

In my previous two posts, I described how to calculate the number of kanbans (Post 1 and Post 2). However, this calculation is complex, and the result is nothing more than a very rough estimate. Hence my preferred method for determining the number of kanbans is, broadly speaking, „just take enough, and then see if you can reduce them.“ In this post, I would like to explain this approach and also discuss how and when to update the number of kanbans.

(EN) How Many Kanbans? – The Kanban Formula, Part 2

Oktober 11, 2025Mai 11, 2014 von Christoph Roser

This is the second post on kanban calculation (if possible, please read the first post on kanban calculation first). There are two possible approaches. First, you can calculate the number of kanbans using a kanban formula (due to its length, split into a first post and this second post). Alternatively, you can estimate the number of kanbans and adjust the system as it is running (as shown in a third post).

(EN) How Many Kanbans? – The Kanban Formula, Part 1

Oktober 11, 2025Mai 4, 2014 von Christoph Roser

One frequent and tricky question when designing a pull system is to determine how many kanbans to use in the system. There are two possible approaches. First, you can calculate the number of kanbans using a kanban formula. Due to the length of the process, I have broken this into two posts (For the second part click here). Alternatively, you can estimate the number of kanbans and adjust the system as it is running (as shown in a third post).

(EN) The Problem of Losing Kanban – Different Kanban Types

Oktober 11, 2025April 20, 2014 von Christoph Roser

Pull production using Kanban is one of the major achievements of the Toyota Production System and hence lean manufacturing. The work in progress is limited by the number of Kanban. Overproduction is avoided by producing only if a part is taken out of the supermarket and the Kanban card is returned to the start of production. However, this Kanban system works only if the Kanban returns to the start of production. Losing Kanban means not reproducing goods sold. In this post I would like to talk about different methods to prevent the loss of Kanban, including different Kanban types.

(EN) Simple Triangle Kanban System for Office Supplies

Oktober 11, 2025Dezember 22, 2013 von Christoph Roser

Kanban systems are a huge help in industry, ensuring a steady availability of parts and products without excess stock. However, Kanbans are not necessarily limited to industrial use. In this post I will describe a simple Kanban system for office supplies. This system is also sometimes known as triangle kanban. One benefit of this system is that it will improve the availability of pens, paper, and other supplies. However, a second major benefit is that this provides a risk-free opportunity to train your people in creating and using Kanban systems.

(EN) Ten Rules When to Use a FIFO, When a Supermarket – The Rules

Oktober 11, 2025Dezember 15, 2013 von Christoph Roser

Lean manufacturing pull systems use both FIFO lanes and supermarkets to manage the material and information flow. In my previous post we covered the basics about supermarket and FIFO lanes. Now we go into details about the ten rules when to use a supermarket instead of a FIFO.

(EN) Ten Rules When to Use a FIFO, When a Supermarket – Introduction

Oktober 11, 2025Dezember 8, 2013 von Christoph Roser

It is generally accepted knowledge that a lean manufacturing pull system uses both FIFO lanes and supermarkets to manage the material and information flow. However, there are few guidelines on when to use a supermarket and when to use a FIFO lane. This post is the first of a two-part series that will give ten general rules of thumb for when to use a supermarket instead of a FIFO lane. The second post will go into more detail about the ten rules.