Run Kanban Replenishment Audit — Free

Audit Setup and Scope

Kanban loop and part family identified critical (required)

Verify the audit scope clearly identifies the Kanban loop, SKU/part family, and replenishment point being inspected.

Yes No N/A

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.

Yes No N/A

Audit date and shift recorded

Record when the audit was performed and which shift or operating period was observed.

Note (optional)

Audited area free of immediate safety hazards critical (required)

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.

Yes No N/A

Kanban Card Flow

Cards present for all active replenishment locations critical (required)

Verify each active Kanban location has the correct number of cards or signals assigned to it.

Yes No N/A

Card return path follows defined process critical (required)

Confirm used cards are returned through the defined collection point or electronic workflow without bypassing the standard route.

Yes No N/A

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

Inspect for missing cards, duplicate cards, illegible labels, or physical damage that could disrupt replenishment control.

Yes No N/A

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 critical (required)

Verify the physical or system trigger level matches the approved replenishment setting for the audited item.

Yes No N/A

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.

Yes No N/A

Actual on-hand quantity at time of audit

Record the observed on-hand quantity for the audited item at the time of inspection.

Note (optional)

Observed quantity at or above minimum trigger level critical (required)

Confirm the observed quantity is not below the approved minimum trigger level unless an approved exception exists.

Yes No N/A

Replenishment signal generated at correct trigger point critical (required)

Verify the pull signal was generated when the defined trigger point was reached, not after stockout or before the trigger.

Yes No N/A

Pull System Adherence

Replenishment initiated only by authorized pull signal critical (required)

Confirm replenishment starts only after a valid Kanban signal, card, or system trigger is received.

Yes No N/A

No evidence of push replenishment or overproduction critical (required)

Check for replenishment performed without a trigger, excess inventory above standard, or production ahead of demand.

Yes No N/A

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.

Yes No N/A

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 critical (required)

Compare the observed physical quantity to the system record, board count, or bin label quantity.

Yes No N/A

Bins, locations, and labels clearly identified

Verify bin locations, part numbers, and replenishment labels are legible and match the correct item.

Yes No N/A

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.

Yes No N/A

Inventory discrepancy documented

Record any mismatch between physical and system quantities, including suspected root cause.

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Run: Kanban Replenishment Audit

Audit Setup and Scope

Kanban Card Flow

Trigger Levels and Replenishment Signals

Pull System Adherence

Inventory Accuracy and Visual Controls

Get your results