Overcoming Inventory Challenges with 5S and Kanban | Episode 5
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- Опубликовано: 19 сен 2022
- Follow the lean journey of a growing donut shop as it troubleshoots the adoption of lean manufacturing tools and principles.
EPISODE 5 SUMMARY
Inventory management was a key problem when opening up the donut shop. It consumed a TON of Daniel's brainpower and attention and had to be dealt with early on so that he was free to focus on other problems and leading the donut team. We eventually setup a kanban system to serve as our purchasing system.
ABOUT THE LEAN DONUT SHOP
The Lean Donut Shop is a real-life company (aka The Donut Theory, thedonuttheory.com) that was birthed in 2020 in the middle of the COVID-19 pandemic. Starting in a home kitchen, the business took off! It grew into a temporary shared commercial kitchen and a 1947 Ford Half Ton mobile donut truck, and later into a brick-and-mortar storefront in the Fall of 2021.
LEARN MORE ABOUT LEAN
To learn more about lean manufacturing, visit leansmarts.com for quality resources and training. You can also enroll in our online video training at the Lean Smarts Academy to make lean training simple, fun, and engaging for all!
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Great video
Thanks for this content! Can you go into more detail on all your kanban/card systems on the wall?
Hi Kiera! Yes. Basically, we had two types of kanban in use at the donut shop. One was for raw material/ingredients. (This included cleaning supplies, packaging, and anything else we had to purchase to conduct the business.) The kanban card has an inventory trigger point written on it that explains where to place the kanban card among the inventory. For example, it might be the last unit on the shelf, or the 3rd-to-last unit, etc. Other times, I had one kanban card for each unit such as in the case of some cleaners. There's no one way to do it, however I tried to be consistent. The total quantity of inventory allowed on the shelf and the trigger point determined for each item/ingredient was based on how frequently I planned to go to the store/purchase online and our sales volume. It's takes a little time and trial-and-error to dial it in. But once it's set, it's a dream. You only need to adjust the kanban if your volumes change significantly. The other type of kanban was for kitchen prep activities. This kanban was physically placed on prepped food containers. When a container was opened/used, the card was placed centrally in our stall on a wall where it signaled the need to produce more to the team. This is explained in episode 6, which was just released today. The quantity of kitchen prep kanban and "trigger points" were again determined by sales volume, how quickly we could realistically replenish stock, and food expiry limitations. I hope this helps! There's another video here that explains kanban in-depth. ruclips.net/video/Levkx8f0qL4/видео.html. Additionally, you might look into GembaDocs as a simple software tool for creating kanban cards for printing. I didn't know about GembaDocs at the time but would have absolutely used it!
@@LeanSmarts thank you so much for such a detailed and thorough response!! Such good info!