a5c-ai Kanban System Designer
Overview
The Kanban System Designer skill provides comprehensive capabilities for designing and implementing pull-based production control systems. It supports kanban sizing, WIP limit determination, supermarket design, and electronic kanban configuration for efficient material flow.
Capabilities
- Kanban sizing calculation
- WIP limit determination
- Supermarket design
- Signal mechanism configuration
- Pull system simulation
- Heijunka box design
- Electronic kanban (e-kanban) configuration
Used By Processes
- LEAN-004: Kanban System Design
- TOC-002: Drum-Buffer-Rope Scheduling
- CAP-002: Production Scheduling Optimization
Tools and Libraries
- Kanban software APIs
- Inventory management systems
- Simulation tools
- Visual board platforms
Usage
skill: kanban-system-designer
inputs:
product_family: "Widget Assembly"
demand_data:
average_daily: 500
peak_daily: 750
variability: "medium"
lead_time_data:
replenishment_time: "4 hours"
safety_factor: 1.5
container_size: 50
outputs:
- kanban_quantity_calculation
- supermarket_layout
- signal_card_design
- wip_limits
- implementation_plan
Workflow
- Analyze Demand - Review historical demand patterns and variability
- Calculate Kanban - Determine number of kanbans needed
- Design Signals - Create visual or electronic signal mechanisms
- Set WIP Limits - Establish limits for each process step
- Configure Supermarkets - Design inventory storage points
- Implement and Tune - Deploy system and adjust parameters
Kanban Calculation Formula
Number of Kanbans = (Daily Demand x Lead Time x Safety Factor) / Container Size
Where:
- Daily Demand = Average units consumed per day
- Lead Time = Time to replenish (in days)
- Safety Factor = Buffer for variability (typically 1.0-2.0)
- Container Size = Units per kanban container
Integration Points
- ERP/MRP systems
- Manufacturing Execution Systems
- Inventory management platforms
- Visual management displays