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Run: Kanban Replenishment Audit

Audit Kanban replenishment with a clear checklist for card flow, trigger levels, and pull compliance. Catch stockout risks early and keep inventory signals a...

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Kanban Card Flow

Kanban cards are present at all active pull points critical (required)

Yes No N/A

Cards are returned promptly after use

Assess whether cards are returned to the replenishment point without delay.

Card routing matches the defined process critical (required)

Yes No N/A

No missing, damaged, or outdated cards observed critical (required)

Yes No N/A

Trigger Levels and Replenishment Signals

Trigger level is clearly defined for each item critical (required)

Yes No N/A

Observed inventory is at or above the minimum trigger level critical (required)

Yes No N/A

Replenishment signal is generated when the trigger level is reached critical (required)

Yes No N/A

Trigger levels reflect current demand and lead time

Evaluate whether trigger levels are aligned with actual consumption and replenishment lead time.

Pull System Compliance

Replenishment occurs only in response to a pull signal critical (required)

Yes No N/A

No overproduction or premature replenishment observed critical (required)

Yes No N/A

WIP limits are visible and followed

Yes No N/A

Operators understand the pull rules for replenishment

Assess whether team members can explain when and how replenishment should occur.

Inventory Accuracy and Visual Controls

Visual controls clearly show replenishment status

Yes No N/A

Physical inventory matches the Kanban system quantity critical (required)

Yes No N/A

Locations are labeled and easy to identify

Yes No N/A

Replenishment board or signal area is organized and up to date

Evaluate the condition and accuracy of the visual management area.

Exceptions and Corrective Actions

Any stockouts or near-stockouts observed critical (required)

Yes No N/A

Any delayed replenishment events observed

Yes No N/A

Corrective actions are assigned to an owner critical (required)

Yes No N/A

Follow-up date is documented for open issues

Note (optional)

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