Free template
Updated
Kanban card template
A kanban card is the signal that makes a pull system work: nothing is made or moved without one. A production kanban tells a process to make one container of a part, and a withdrawal kanban tells a material handler to move one container from the store to the process that uses it. This template has six production kanbans on page 1 and six withdrawal kanbans on page 2, each with the part number, description, where it is made or taken from, where it goes, the quantity per container, the container type, a card number such as 3 of 5 and a space for a photo or barcode. Page 3 has the formula for how many cards a loop needs, a register of every card in circulation and the rules for running the cards.
Free to use: print it, copy it and edit it for your team. Enter your name and work email once to download.
Six production kanban cards in a two by three grid with dashed cut lines, each with part number, description, where it is made, quantity per container, container type, location, materials, lot size, card number and a space for a photo or barcode.6 production kanbans6 withdrawal kanbansCard __ of __ numberingPhoto or barcode spaceCard-count formulaCard registerRules for the cards
When to use it
When to use kanban cards
- To replace a schedule pushed to each process with a pull loop between a supplying process and the one that uses its parts.
- For parts used steadily, such as brackets, fasteners or subassemblies that go into most products.
- Between a supermarket and the line, so material handlers deliver what was used rather than what someone guessed.
- When a paper system is the right first step before any electronic signal, or where cards work better than screens.
- Not for one-off or very irregular parts, which are better made to order.
How to fill it in
- 1
Choose the loop
Pick one part and one loop: the process that makes it, the store where full containers wait and the process that uses them.
- 2
Size the loop
Work out the number of cards with the formula on page 3: daily demand × lead time × (1 + safety factor) ÷ quantity per container, rounded up.
- 3
Fill in the cards
Write the part number, description, where it is made or taken from, where it goes, the quantity and the container. Number the cards 1 of 5, 2 of 5 and so on.
- 4
Print and protect them
Print production and withdrawal kanbans on different colors of card, cut them out and laminate them or put them in sleeves.
- 5
Record every card
Write each loop in the register on page 3, so a lost card is noticed and nobody adds cards without updating it.
- 6
Run the rules and review the loop
Follow the rules on page 3. Review the number of cards when demand or lead time changes, and take cards out when the loop runs well.
A filled-in example
Illustrative, not a benchmarkAn example: a kanban loop between a stamping press and the assembly line that uses its brackets.
The example loop and its card count
- 1
Assembly empties a container of 50
- 2
Its card goes to the press
- 3
The press makes 50 brackets
- 4
The full container returns to the store
↻ Back to the store: the loop repeats
Cards = demand × lead time × (1 + safety factor) ÷ container
- 400 a day × 0.5 day × 1.1 ÷ 50 = 4.4= 5 cards
- The assembly line uses about 400 brackets a day, in containers of 50.
- From the moment a container is emptied, it takes about half a day for its card to reach the press, for the brackets to be made and for the full container to be back in the store.
- With a safety factor of 0.1: 400 × 0.5 × 1.1 ÷ 50 = 4.4, so 5 production cards, numbered 1 of 5 to 5 of 5.
- After a month the store has never dropped below two full containers, so the team takes one card out of the loop and updates the register.
The press makes brackets only when a card comes back, the store never holds more than the cards allow, and the register shows every card in the loop.
Common mistakes
Making without a card
Running extra parts because the press is free fills the store and breaks the loop. No card, no production.
Too many cards, never reviewed
Cards are inventory. Size the loop from real numbers and take cards out as lead time comes down.
Lost cards nobody misses
A card that goes missing means a container that is never replaced. Keep the register and check it regularly.
Batching cards
Holding cards until there are enough for a big run adds lead time. Make in the order the cards arrive, or level the work with a heijunka box.
Starting with the hardest part
Begin with a steady, simple part, learn how the loop behaves, then add more.
Download the template
Free to use: print it, copy it and edit it for your team. Enter your name and work email once to download.
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FAQ
Kanban card template: common questions
A card that authorizes work in a pull system. A production kanban tells a process to make a container of a part, and a withdrawal kanban tells someone to move a container from the store to the process that uses it. Nothing is made or moved without a card.
A production kanban stays in the loop between a process and the store it fills, and signals that the process should make more. A withdrawal kanban, also called a conveyance or move kanban, travels between the store and the next process, and signals that a container should be moved. Many simple loops use only production kanbans.
A common formula is daily demand × replenishment lead time in days × (1 + safety factor) ÷ quantity per container, rounded up. Lead time is the whole time for a card to go around the loop. Page 3 of this template has the formula and a register for the result.
At least the part number and description, where the part is made or taken from, where it goes, the quantity per container, the container type and the card number, such as 3 of 5. A photo of the part or a barcode helps people match the card to the container.
Not quite. Kanban cards control material in a pull system on the shop floor. A kanban board shows tasks in columns such as to do, doing and done, and is used to manage work such as projects and actions.
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- Cost per unit worksheet (manufacturing cost per good unit)One product's cost per good unit by materials, labor, machine and overhead, the gap to target, and which cost lever is worth most a year.
- RCM worksheet (failure mode and task selection)Failure modes classed as hidden, safety, operational or non-operational, then a task chosen for each: condition-based, discard, failure-finding, redesign or run to failure.
- Error-proofing verification log (daily master-sample check)Each poka-yoke device proved every day or week with a known-bad sample, with missed checks counted and the hours and parts at risk worked out when one fails.
- Training matrix template with expiry datesPeople by required trainings with expiry dates, OK, due, expired and missing flags, compliance by person and area, cover per training and a renewal list.
- Defect catalogue template with boundary samplesEvery defect with a definition, a class and the reason for it, measured accept and reject limits by zone, boundary samples, a defect log with DPU and Pareto, and an inspector agreement check.
- I-MR chart template (individuals and moving range)Up to 100 single readings with moving ranges, limits from a baseline, five run-rule flags, both charts, a second phase and a reaction log.
- Kaizen event preparation checklistEverything that has to be ready before a kaizen event and done after it: 44 items with owners and due dates from 6 weeks before day 1 to 30 days after, five go or no-go gates and a day-by-day agenda.
- Attribute control chart template (p, np, c and u charts)p, np, c and u charts in one workbook: a chart selector, a sample size check, limits for each subgroup, signal flags and four worked examples.
- Critical spare parts list and stocking levelsAssets ranked by consequence, each part classed and given a stocking policy, and min and max worked out from usage and lead time, with the downtime each stock-out would cost.
- HACCP plan template: hazard analysis and CCP worksheetThe Codex 12 steps in one workbook: team and product, process steps checked on site, hazard analysis with the CCP decision tree, the CCP table with completeness checks, an allergen matrix and a verification schedule.
- Forklift operator training and evaluation recordPer-operator training and evaluation record, a register with three-year due dates and refresher triggers, and a weighted practical evaluation scoresheet.
- REBA worksheet (Rapid Entire Body Assessment)Score up to six postures with REBA: body-part drop-downs, Tables A, B and C as lookups, final score and action level, and a before and after comparison.
- Mock recall template: traceability exercise worksheetTrace a finished lot back to every input lot and forward to every first customer, reconcile the quantities against a tolerance and time it against your target.
- ISO 9001 internal audit checklist (production area)46 audit questions for the production floor in 11 processes, each with its ISO 9001:2015 clause, what evidence to look for and the sample to take, plus five defined grades, a findings log, a finding report and a summary by clause.
- ISO 45001 internal audit checklist44 audit questions for the plant floor in 16 safety topics, each with its ISO 45001:2018 clause, the evidence to look for and the sample to take, plus 12 worker interview prompts, a findings log and a summary by clause.
- Food plant GMP inspection checklist (21 CFR 117 subpart B)55 checks in the order of 21 CFR 117 subpart B, each citing its paragraph and saying what to look at, with a grade, finding, owner and due date; results by section and grade, a walk route and a bakery example.
- Master sanitation schedule with pre-op verificationA master list of cleaning tasks by area and equipment with frequency, chemical, lockout, who and next due date, a weekly on-time count, and the pre-operational verification log with a release step.
- Overhead crane inspection checklist: frequent and periodic34 crane checks tied to OSHA 1910.179: an operator's pre-shift card, frequent and periodic inspections with signed records, a deficiency and tag-out log, and a register of next due dates.
- Measurement uncertainty budget templateA GUM uncertainty budget: Type A and B rows, divisors by distribution, sensitivity coefficients, uc, νeff, k from the t-table, U, TUR and a guard band check.
- Maintenance job plan templateOne job planned on one sheet: steps and craft hours, parts checked against stock, tools, lockout and permits, documents, a ready check for the schedule, and technician feedback.
- Video time study filming checklistA pre-shoot checklist and shot log for filming a time study on video: camera, light, people, settings, power and review.
- OSHA compliance calendar (general industry)37 recurring federal OSHA duties with the paragraph, interval, owner, next due date and an overdue flag, plus a 12-month view and counts by owner.
- Energy use and EnPI trackerMonthly electricity, gas and fuel in one unit, a 12-month regression baseline, expected against actual energy for each month, an EnPI ratio, the running saving and the tests that say whether the model can be trusted.
- Pugh matrix templateCompare up to 8 concepts with a datum as better, same or worse on up to 12 criteria, flag must-haves, and carry the strongest into a second round.
- Machine guarding inspection sheetA machine register with due dates and a status per machine, 21 checks tied to OSHA 1910.212, .219 and .147, a guard opening check against Table O-10, and an action log.
- Condition monitoring route sheetA route of measuring points with baselines, alert and alarm limits, a check interval from the P-F interval, readings with rising and overdue flags, and an exceptions list worst first.
- Fire extinguisher inspection logOne row for every portable extinguisher: hydro test interval from OSHA Table L-1, annual and 6-year due dates, a 12-month check grid and open issues.
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A shift handover sheet, a red tag log, a changeover checklist for one machine: if your team uses it on the floor, ask.