We use laminated KanBan cards for components used in assembly of our end product. The card is a mini-router, with inspections that have to be signed off, as proof that hardness checks were done at certain steps. Today we use a piece of masking tape on the side of the card to allow for the sign-offs, that is stripped off by the Planner when the card is returned to the rack. This is a very high volume operation, with many cards being processed a day.

The problem with this is that inspection stamp ink is easily smeared and is sometimes missing altogether by the time the next operation is done. That means running back to the log books to determine if the met check was done. We've fooled around with different tapes and inks, but the problem continues.

How do others using KanBan cards deal with tracking sign-offs for operations or inspections?

Food for thought. If this is a high volume assembly, is there any way to make the process "flow" in order to eliminate the need for the cards. It is interesting that many "future state" maps typically have plenty of supermarkets and such, but don't really look at what it would take to make the product flow through the process.

Have you tried grease pencils?

One option is to make it very clear that when a kanban is attached, all respective operations have been completed, including inspection activities. Detail these inspection steps in the work instructions. Passing the product to the next operation should signify that the operator has performed all the necessary steps following the "don't get it, don't make it, don't send it" concept. If a piece of tape or a stamp is acceptable to signify compliance to the work instructions, then following this same thought process, the act of attaching a card to the parts could signify the same thing.

Using the kanban as a router doesn't make much sense to me and seems to complicate the issue. Any additional information could prove useful.

Wayne

Thanks Wayne.
We implemented this years ago and I don't think we have seriously looked at it in since then. It may be time for a program review.