Kanban System Review Checklist
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System Overview & Goals
Assess the overall purpose and effectiveness of the Kanban system in achieving manufacturing objectives. This section covers alignment with broader business goals.
Briefly describe the primary goals of this Kanban system within the manufacturing process.
What is the target Overall Equipment Effectiveness (OEE) that this Kanban system aims to support?
Does this Kanban system align with the overall Manufacturing Strategy?
Date of last strategic review linking Kanban to manufacturing goals.
Summarize any significant changes in manufacturing goals since the last Kanban System Review.
Is the Kanban system achieving its intended goals?
If the answer to the previous question is 'No' or 'Needs Improvement', briefly explain why.
Board Design & Visualization
Review the physical or digital Kanban board layout, including columns, swimlanes, and card design, to ensure clarity and efficiency.
Number of Columns
Description of Swimlanes (if any)
Board Type (Physical/Digital/Hybrid)
Color Coding Used? (Select all that apply)
Describe any visual cues/icons used on cards
Ease of Understanding (Board clarity for new users)
Attach a Photo/Screenshot of the Kanban Board
Card Definition & Content
Evaluate the information captured on Kanban cards to ensure they provide sufficient detail for efficient workflow management.
Part Number
Description
Quantity Required
Due Date
Priority Level
Special Instructions / Notes
Material Type
Workflow & Cycle Times
Analyze cycle times for each stage of the workflow and identify bottlenecks or areas for improvement.
Average Cycle Time - Stage 1 (e.g., Cutting)
Average Cycle Time - Stage 2 (e.g., Assembly)
Average Cycle Time - Stage 3 (e.g., Quality Check)
Average Total Cycle Time (all stages)
Identify Bottlenecks: Describe any observed bottlenecks in the workflow.
Bottleneck Severity (if applicable)
Proposed Solutions for Bottlenecks: Outline any proposed solutions to address identified bottlenecks.
Date of Last Cycle Time Measurement
Percentage Change in Total Cycle Time (vs. last review)
Work in Progress (WIP) Limits
Verify the appropriateness and effectiveness of WIP limits across all stages of the manufacturing process.
Current WIP Limit - Stage 1 (e.g., Cutting)
Current WIP Limit - Stage 2 (e.g., Assembly)
Current WIP Limit - Stage 3 (e.g., Finishing)
Average WIP Levels - Stage 1
Average WIP Levels - Stage 2
Average WIP Levels - Stage 3
Are current WIP limits optimal?
Explanation if WIP Limits are not optimal.
Replenishment & Ordering
Review the replenishment signals, order points, and ordering processes to ensure material flow is responsive and accurate.
Current Safety Stock Levels (for critical materials)
Reorder Point (ROP) Accuracy (average deviation)
Replenishment Signal Type
Describe any discrepancies between actual material flow and replenishment signals.
Date of last replenishment process review
Lead Time Accuracy (average days)
Supplier Performance - On-Time Delivery (Critical Materials)
Team Performance & Training
Assess team understanding and adherence to Kanban principles, identify training needs, and gather feedback for continuous improvement.
Team Member Understanding of Kanban Principles (1-5, 1=Poor, 5=Excellent)
Frequency of Kanban Training Sessions (per month)
Describe any observed deviations from established Kanban processes by team members.
Which of the following training topics are needed? (Select all that apply)
How effective is the current method for sharing Kanban updates and changes?
What suggestions do team members have to improve Kanban understanding and adherence?
Date of last Kanban training session.
Metrics & Reporting
Examine key performance indicators (KPIs) related to the Kanban system and identify trends or areas requiring attention.
Average Lead Time (Days)
Cycle Time for Stage 1 (Minutes)
Number of Cards Completed per Shift
Percentage of Cards Delivered On Time
Brief Summary of Recent Metric Trends
Are metrics being tracked and visualized effectively?
Attach KPI Report (if applicable)
Date of Last KPI Review
System Adherence & Continuous Improvement
Evaluate the extent to which the team is consistently following Kanban processes and explore opportunities for refinement.
Percentage of cards fully compliant with standard card format.
How frequently are Kanban reviews conducted?
Describe any deviations from standard Kanban practices observed.
Which improvement suggestions have been implemented since the last review?
Date of last team training on Kanban principles.
Document any roadblocks or challenges preventing full adherence to Kanban principles.
Overall, how satisfied are team members with the current Kanban system?
Upload any relevant documentation supporting observations (e.g., process diagrams, training materials)
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