Kanban CalculatorKanban Card Calculator
Pull system replenishment sizing
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What Kanban Cards Control
A kanban card is a replenishment signal. The number of cards controls how much material can be in the loop between a consuming process and a supplying process.
Too few cards cause stockouts. Too many cards hide problems by creating excess inventory.
Kanban cards needed
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Maximum WIP
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Days of supply
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Safety stock in loop
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What is a kanban card calculator?
A kanban card calculator estimates how many replenishment signals a pull system needs. The common formula is Cards = Demand x Lead Time x Safety Factor / Container Quantity. The result is rounded up because a physical or digital kanban loop can only use whole cards.
Use this after you know the demand rate, replenishment lead time, and standard container quantity. Pair it with a Value Stream Map to see where pull loops belong, and with the Takt Time Calculator to confirm demand pace.
Related tools
- Value Stream Map - identify supermarkets and replenishment loops
- Takt Time Calculator - calculate customer demand pace
- EPEI Calculator - estimate mixed-model replenishment interval