KANBAN SYSTEM REVIEW CHECKLIST

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--- SYSTEM OVERVIEW & 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? (Yes, No, Partially)
[ ] 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? (Yes, No, Needs Improvement)
[ ] If the answer to the previous question is 'No' or 'Needs Improvement', briefly explain why.

--- BOARD DESIGN & VISUALIZATION ---
[ ] Number of Columns
[ ] Description of Swimlanes (if any)
[ ] Board Type (Physical/Digital/Hybrid) (Physical, Digital, Hybrid)
[ ] Color Coding Used? (Select all that apply) (Priority, Type of Work, Status, Team, None)
[ ] Describe any visual cues/icons used on cards
[ ] Ease of Understanding (Board clarity for new users) (Very Easy, Easy, Neutral, Difficult, Very Difficult)
[ ] Attach a Photo/Screenshot of the Kanban Board

--- CARD DEFINITION & CONTENT ---
[ ] Part Number
[ ] Description
[ ] Quantity Required
[ ] Due Date
[ ] Priority Level (High, Medium, Low)
[ ] Special Instructions / Notes
[ ] Material Type (Raw Material, Component, Finished Good)

--- WORKFLOW & CYCLE TIMES ---
[ ] 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) (Minor, Moderate, Significant)
[ ] 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 ---
[ ] 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? (Yes, No, Unsure)
[ ] Explanation if WIP Limits are not optimal.

--- REPLENISHMENT & ORDERING ---
[ ] Current Safety Stock Levels (for critical materials)
[ ] Reorder Point (ROP) Accuracy (average deviation)
[ ] Replenishment Signal Type (Kanban Card, Digital Signal, Scheduled Order, Manual Request)
[ ] 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) (Excellent (98-100%), Good (90-97%), Average (80-89%), Needs Improvement (Below 80%))

--- TEAM PERFORMANCE & TRAINING ---
[ ] 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) (New Team Member Onboarding, Advanced Kanban Techniques, Problem Solving and Bottleneck Analysis, Data Analysis and Reporting)
[ ] How effective is the current method for sharing Kanban updates and changes? (Very Effective, Effective, Neutral, Ineffective, Very Ineffective)
[ ] What suggestions do team members have to improve Kanban understanding and adherence?
[ ] Date of last Kanban training session.

--- METRICS & REPORTING ---
[ ] 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? (Yes, No, Partially)
[ ] Attach KPI Report (if applicable)
[ ] Date of Last KPI Review

--- SYSTEM ADHERENCE & CONTINUOUS IMPROVEMENT ---
[ ] Percentage of cards fully compliant with standard card format.
[ ] How frequently are Kanban reviews conducted? (Daily, Weekly, Bi-weekly, Monthly, Less than Monthly)
[ ] Describe any deviations from standard Kanban practices observed.
[ ] Which improvement suggestions have been implemented since the last review? (Improved Card Design, Adjusted WIP Limits, Increased Training, Board Layout Changes, None)
[ ] 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? (Very Satisfied, Satisfied, Neutral, Dissatisfied, Very Dissatisfied)
[ ] Upload any relevant documentation supporting observations (e.g., process diagrams, training materials)

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