Kanban Replenishment Audit

Inspection template for auditing Kanban replenishment processes, including card flow, trigger levels, and pull system adherence.

Audit Setup and Scope

• Kanban loop and part family identified
  Verify the audit scope clearly identifies the Kanban loop, SKU/part family, and replenishment point being inspected.
• Current standard work or visual standard available at point of use
  Check that the current Kanban standard work, visual board, or replenishment instructions are available and match actual practice.
• Audit date and shift recorded
  Record when the audit was performed and which shift or operating period was observed.
• Audited area free of immediate safety hazards
  Confirm the work area is free of obvious trip hazards, blocked aisles, or unsafe conditions that could interfere with replenishment flow. Reference OSHA 29 CFR 1910 Subpart D and, where applicable, NFPA 101 egress requirements.

Kanban Card Flow

• Cards present for all active replenishment locations
  Verify each active Kanban location has the correct number of cards or signals assigned to it.
• Card return path follows defined process
  Confirm used cards are returned through the defined collection point or electronic workflow without bypassing the standard route.
• No missing, duplicate, or damaged cards observed
  Inspect for missing cards, duplicate cards, illegible labels, or physical damage that could disrupt replenishment control.
• Card scan or handoff time within standard
  Measure the elapsed time from consumption trigger to card receipt by the replenishment owner.
• Card flow exceptions documented
  Record any exceptions such as lost cards, manual overrides, emergency pulls, or temporary substitutions.

Trigger Levels and Replenishment Signals

• Trigger level matches approved min/max setting
  Verify the physical or system trigger level matches the approved replenishment setting for the audited item.
• Trigger level visible and unambiguous to operators
  Confirm the trigger point is clearly marked on the bin, rack, board, or system screen so operators can identify when to pull.
• Actual on-hand quantity at time of audit
  Record the observed on-hand quantity for the audited item at the time of inspection.
• Observed quantity at or above minimum trigger level
  Confirm the observed quantity is not below the approved minimum trigger level unless an approved exception exists.
• Replenishment signal generated at correct trigger point
  Verify the pull signal was generated when the defined trigger point was reached, not after stockout or before the trigger.

Pull System Adherence

• Replenishment initiated only by authorized pull signal
  Confirm replenishment starts only after a valid Kanban signal, card, or system trigger is received.
• No evidence of push replenishment or overproduction
  Check for replenishment performed without a trigger, excess inventory above standard, or production ahead of demand.
• Replenishment lead time within standard
  Measure the elapsed time from signal receipt to replenishment completion and compare it to the approved standard.
• Temporary expedites approved and documented
  Verify any expedite, substitution, or manual override was approved by the designated owner and documented with reason and duration.
• Operators understand pull rules
  Confirm operators can explain when to pull, where to place cards, and what to do when a card or signal is missing.

Inventory Accuracy and Visual Controls

• Physical count matches system or board quantity
  Compare the observed physical quantity to the system record, board count, or bin label quantity.
• Bins, locations, and labels clearly identified
  Verify bin locations, part numbers, and replenishment labels are legible and match the correct item.
• Visual controls maintained and not obscured
  Check that floor markings, shadow boards, min-max lines, and signal indicators are visible and not blocked or faded.
• Inventory discrepancy documented
  Record any mismatch between physical and system quantities, including suspected root cause.