A dual-card Kanban system

The dual-card Kanban system makes use of two Kanban cards. The two Kanbans are a conveyance card and a vendor card. In a single-card Kanban system, we assume that the required quantity of inventory is available in the inventory department. In the dual card system, the required inventory is obtained from a vendor and a vendor authorization Kanban is used in the transactions.

The functioning of a dual card system is shown in Figure and can be described in the following steps:

• The process of working of a conveyance card in this system is similar to that in the single-card system. A conveyance Kanban is put in an empty tray at point A and a material handling agent moves it to point B in the inventory department. The tray is collected at point C and sent to point D in the assembling area similar to the single card system.

• In this system, the vendor Kanban is introduced at point X, authorizing a vendor (at point Y) to deliver the materials that are specified in the card.

• After receiving the card, the vendor delivers the materials into the empty trays that are available at point Z.

Figure: Dual-Card Kanban System

• The filled container is placed in the bins at the position X. It remains at this position till a conveyance card arrives from Point B to Point C, authorizing the movement of material from Point C to Point D.

• Once the container is authorized to move, the vendor Kanban is removed and sent to the vendor and cycle repeats itself.

From the above procedure, it can be observed that Kanbans operate in closed loops and they continue to operate until the materials manager withdraws them. The number of Kanbans can be altered according to the estimated demand for a product. If the demand for the product increases, a larger number of Kanbans are used to meet the increased demand. Similarly, the number of Kanbans can be reduced if the demand for the product decreases. Thus, the system enables both production control and inventory control in materials management. But the limitation of the system is that it depends excessively on the people involved in the process. The failure of a vendor to supply the required amount of materials and missing a Kanban are serious threats to the successful running of the system.                 

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