In the late 1940s, Toyota found a better engineering process from an unlikely source: the supermarket. They noticed that store clerks restocked a grocery item by their store’s inventory, not their vendor’s supply.
Only when an item was near sellout did the clerks order more. The grocers’ “just-in-time” delivery process sparked Toyota engineers to rethink their methods and pioneer a new approach—a Kanban system—that would match inventory with demand and achieve higher levels of quality and throughput.
So how’d they do all that?
In simplest terms, by better communication through visual management.
Kanban is Japanese for “visual signal” or “card.” Toyota line-workers used a kanban (i.e., an actual card) to signal steps in their manufacturing process. The system’s highly visual nature allowed teams to communicate more easily on what work needed to be done and when. It also standardized cues and refined processes, which helped to reduce waste and maximize value.
A new application of Kanban emerged for knowledge work as early as 2005, and an inquisitive community formed in 2007 around the leadership of David J. Anderson, Jim Benson, Corey Ladas and others. Their resulting body of knowledge was influenced not only by the Toyota Production System but also by the work of W. Edwards Deming, Eliyahu Goldratt, Donald Reinertsen and other thought leaders.
Kanban Today and Why it Works
Today’s workforce may be armed with retina-worthy smartphones and tablets, but plenty of information still comes our way as words on a screen. Emails, spreadsheets, task lists—text is everywhere. While it fits certain scenarios, textual information is not a one-size-fits-all communication vehicle. Its effectiveness is lower than you might think.
It starts with your brain.
A picture is worth a thousand words for scientific reasons: The brain processes visual information 60,000 times faster than text. Forty percent of all nerve fibers connected to the brain are linked to the retina. Visual information comprises 90 percent of the data that comes to our brain, suggesting that our neurological pathways might even prefer pictorial displays over text.
Kanban helps you harness the power of visual information by using sticky notes on a whiteboard to create a “picture” of your work. Seeing how your work flows within your team’s process lets you not only communicate status but also give and receive context for the work. Kanban takes information that typically would be communicated via words and turns it into brain candy.