KaizumiKaizumi™

Kanban 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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Want an editable copy?

Download the free Kanban Card Calculator template — enter demand, lead time, container size, and safety factor and it sizes the number of kanban cards, maximum WIP, and days of supply. Opens in Excel and Google Sheets.

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.

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