Kanban the Toyota Way: An Inventory Buffering System to Eliminate Inventory

This book is a practical guide for lean practitioners, operations managers, industrial engineers, and supply chain professionals seeking to understand and apply the Toyota Kanban system. Whether you're dealing with production delays, excess inventory, or inconsistent workflows, this book shows you how to implement Kanban as a flexible, visual pull system to restore flow and improve efficiency. Kanban—meaning "sign" or "signboard" in Japanese—is a visual signaling method used in the Toyota Production System (TPS). In a pull-based manufacturing process, Kanban cards signal upstream processes to produce only what is needed, in the quantity needed, and only when it is needed. This prevents overproduction, limits inventory, and maintains flow. There are two core types of Kanban: Production Kanban, which instructs upstream processes on what to produce. Withdrawal Kanban, which tells downstream processes what to pick up or move. Although Toyota aims for zero inventory, real-world disruptions and process gaps require strategic buffering. Kanban provides a practical solution when clean, uninterrupted flow isn't possible—especially when processes are far apart or have mismatched cycle times. This book breaks down the logic, design, and practical use of the Kanban system, helping you identify waste, balance supply with demand, and drive continuous improvement across your operations.