What is a Kanban system?

A Kanban system is a visual workflow and inventory management method that controls production and material replenishment by signalling when to order or produce more items, helping maintain just-in-time inventory levels.

What are live cartons in a Kanban system?

 

Live cartons are pre-packed containers of parts or materials kept at the point of use that trigger replenishment signals as items are consumed, ensuring that stock is replenished efficiently without overstocking.

How does a Kanban live carton system work?

When items in a live carton reach a preset minimum level, a Kanban card or signal is triggered to reorder or restock exactly what is needed, minimising inventory levels and improving supply chain responsiveness.

What are the benefits of using a Kanban live carton system?

Benefits include reduced inventory carrying costs, improved supply-demand flexibility, less warehouse space needed, reduced waste, faster turnaround, and better working capital utilisation.

Is Kanban live carton suitable for all types of industries?

Yes, it is widely applicable in manufacturing, assembly lines, electronics production, automotive, and distribution environments that require lean inventory and efficient stock replenishment.

How does Kanban differ from traditional inventory management?

Kanban uses a pull-based visual signalling system to produce or order only what is needed when needed, unlike traditional push systems which often lead to excess stock and inefficiencies.

Can Kanban live cartons help improve production efficiency?

Yes, by ensuring materials arrive just in time and eliminating stock shortages or surpluses, Kanban live cartons streamline production flow and reduce downtime.

What kind of visual signals are used in Kanban systems?

Common signals include physical Kanban cards, coloured bins, electronic displays, barcode scanning, or RFID tags that indicate when stock replenishment is required.

How does a Kanban system reduce waste?

By limiting overproduction and excess inventory, Kanban ensures materials are used while fresh, reducing scrap, obsolescence, and storage costs.

Does a Kanban live carton system require software?

While traditional Kanban can be manual with cards and bins, many setups now use software or digital tools to track inventory flows and automate replenishment alerts.

What is the role of employees in a Kanban live carton system?

Operators monitor stock levels in live cartons, move Kanban cards to signal replenishment, and help keep the workflow smooth through timely consumption and reporting.

How can Kanban live cartons improve supplier relationships?

Providing clear, timely demand signals allows suppliers to plan production and deliveries more accurately, reducing delays and fostering a reliable supply chain.

Is Kanban live carton scalable for large operations?

Yes, Kanban systems can be tailored and scaled to handle large, complex supply chains with multiple workstations and suppliers.

Does using Kanban live carton help with compliance in the supply chain?

By maintaining accurate and visible inventory levels, Kanban supports traceability, audit readiness, and regulatory compliance in manufacturing and logistics.

Can Kanban live carton systems integrate with other lean manufacturing tools?

Yes, Kanban often works alongside tools like Just-in-Time (JIT), 5S, and Total Productive Maintenance (TPM) to optimise overall operational efficiency.

What challenges might I face implementing a Kanban live carton system?

Potential challenges include employee training, initial system setup, supplier coordination, and ensuring accurate inventory measurement to prevent stockouts or overstocking.

How do I start using a Kanban live carton system in my business?

Begin by analysing your inventory usage, setting appropriate stock levels, designing visual signals, training staff, and working closely with suppliers on timely replenishment.

Can Kanban live cartons reduce warehouse space requirements?

Yes, by reducing the need for large buffer stocks and holding materials only as needed, overall storage space requirements decrease.

What kinds of companies have successfully used Kanban live carton systems?

Automotive manufacturers, electronics assemblers, aerospace companies, and many lean manufacturing organisations have adopted Kanban live cartons to improve efficiency and reduce costs.

How can I get Kanban live carton solutions or support from Action Handling?

You can contact Action Handling through their website or phone to discuss your Kanban system needs, request product information, and arrange support or consultancy services.