Kanban & Pull Systems: Card Counts, Two-Bin Sizing, Supermarket Levels, Replenishment Lead Times & Levelled Schedules
Size a pull system for a fictional plant or hospital store room: kanban card counts, two-bin quantities, supermarket min/max, how lead-time variation changes the loop, levelled production mixes and the stock-vs-stockout trade-off, with every cell checked as you go.
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About this course
In this course you size pull systems for a fictional assembly plant and a clinic store room, step by step in a spreadsheet. You calculate kanban card counts with ROUNDUP, compare container sizes by signals, stock and daily cost, and size two-bin locations in whole packs. You set supermarket Min and Max levels and the flow-rack lanes and floor space they need, read a replenishment log with MEDIAN and PERCENTILE.INC to see how many extra cards slow cycles require, and recalculate card counts as monthly demand changes. You build a levelled mix pattern with MOD and INDEX, weigh changeovers against stock and finish with a loop review dashboard and chart.
Lessons
- The Kanban Formula: How Many Cards a Loop Needs Pro
- Container Sizes: Cards, Signals and Stock in the Loop Pro
- Two-Bin Systems: Bin Sizes, Packs and Refill Signals Pro
- Supermarkets: Min, Max, Lanes and Floor Space Pro
- Lead-Time Variation: Median, 90th Percentile and Cards at Risk Pro
- Demand Changes: Monthly Card Reviews, Adding and Removing Cards Pro
- Levelled Schedules: Mix Patterns, Pitch and Changeovers Pro
- Loop Review Dashboard: Signals, Stockouts and Usage Pro