2 Card Kanban System

Overview

The two types of cards in a 2-card kanban systems are known as a Production Kanban and a
Withdrawal Kanban. They are different cards that must work in harmony with one another.

Description of Production Kanban System

The first type of 2-card kanban is called a Production Kanban (PIK) card, sometimes called a
Production Instruction Kanban card.

A Production Kanban card is a signal authorizing the production of items to replenish those
consumed downstream. These cards specify all the details needed to reproduce consumed
items. Simply put, Production Kanban can be thought of as a make card.

A Production Kanban is often a physical card but can also be an empty container or other
device that communicates instructions. Production Kanban also allow for lot-for-lot
production. In other words, theyre flexible enough to deal with changeover times.
Production Kanban always stay with the producer, meaning they circulate internally.

Finally, Production Kanban cards are removed when the first part is removed from the
container or prior to replacing the Production Kanban with a Withdrawal or move Kanban.

Example of Production Kanban Card

Heres an example of what a Production Kanban may look like.

2. 2-Card Kanban System Page 1

On the left side of the card we see the upstream process information such as the internal
supplier name and production area. This particular card is #1 of 10.

We also see that this particular Production Kanban is for 25 units. Finally, on the right side of
the card we see the point of use information. In other words, where will these parts go after
they are produced. In this example, we see that these parts will be stored in the Final
Assembly Supermarket on row 2 on shelf 7, location 2.

Although it might seem confusing at first glance, the information on a kanban card clearly
specifies what, where, how many, who produces, and who consumes. This information is
highly useful in making sure production flows are synchronized and standard work is not
disrupted.

Description of Withdrawal Kanban System

A Withdrawal kanban controls who moves an item, where its move from and to, when its
moved, and what amount is moved. Now, as you can see, we have emphasized a particular
word in this definitionmove.

While Production Kanban are the currency or money needed to make or produce product,
withdrawal kanban are the currency or money needed to transport product.

So, f youre moving material from one location to another without withdrawal kanban youre
breaking the 2-card kanban system rules.

Example of Withdrawal Kanban Card

Heres an example of a Withdrawal Kanban.

Youll notice that this card is shaded, making it visibly different than the Production Kanban,
which is often white. With this said, many companies use different colors to distinguish
between Production and Withdrawal Kanban.

2. 2-Card Kanban System Page 2

This Withdrawal Kanban is slightly different than the PK example we showed and we did this
to stress the fact that you can, and should, make your kanban cards work for your situation.
Of course, please feel free to use our examples as starting points.

But even though the format is different, the one thing that is the same is that we still have
upstream process info on the left, product information in the middle, and point of use
information on the right.

Relationship Between Production and Withdrawal Kanban

The relationship between Production and Withdrawal Kanban is something many people dont
understand. The often misunderstood fact is that, in a 2-card kanban system, withdrawal and
production kanban are married.

In other words, if we calculate that we need 30 kanban for a particular process, this really
means that we need 30 Production and 30 Withdrawal Kanban cards in order for the system
to work.

The 30 Production Kanban will be used to make product and the Withdrawal Kanban will be
used to move this product.

2. 2-Card Kanban System Page 3