Template

Kanban & Material Replenishment Template (with worksheet)

Interactive worksheet to design simple kanban pull systems and compute reorder points, safety stock (in days), and kanban card counts. Includes pull rules, card lifecycle guidance, a printable kanban card layout, worked examples, and visual supermarket placement tips.

Interactive Tool

Kanban & Material Replenishment Worksheet

Use this worksheet to design a simple visual pull system

This guided worksheet helps you translate average demand, lead time and container sizes into practical reorder points, safety stock (expressed as days of cover) and the number of kanban cards (or containers) to use in a supermarket. It intentionally keeps formulas simple so teams can validate, test, and adapt the numbers to local conditions.

Why this matters

Kanban limits inventory while reducing stockouts by using visual signals and fixed container sizes. Use the worksheet values as a starting point: run them for a few fast-moving parts, try the physical layout, then adjust safety days or container size based on observed variability.

Core formulas (use for the fields below)

  • Reorder point (units) = (Average daily demand × Lead time days) + (Average daily demand × Safety days)
  • Kanban cards needed = ceiling( (Average daily demand × (Lead time days + Safety days)) / Container size )

Worked example

Example: daily demand = 20 units/day, lead time = 3 days, safety = 2 days, container size = 50 units.
Reorder point = (20 × 3) + (20 × 2) = 100 units. Kanban cards = ceil((20 × (3+2)) / 50) = ceil(200/50) = 4 cards (i.e., four containers circulating).

Enter a concise name or code for the item (e.g., Fastener-123).
Where the kanban containers will sit (e.g., Aisle 2 Bin 4).
Use historical usage or a conservative estimate. For intermittent demand, consider smoothing over several weeks.
Time from replenishment trigger to availability (supplier or internal transfer). Use working days that affect replenishment.
How many days of extra cover to hold for variability. Typical starting values: 1–3 days for stable items; increase for high variability or unreliable suppliers.
The physical quantity each kanban container holds. Use the smallest practical standard size to improve turns.
Calculate using formula: (average daily demand × lead time days) + (average daily demand × safety days). Enter the calculated result here so it is saved with the worksheet.
Calculate using formula: ceiling((average daily demand × (lead time days + safety days)) / container size). Enter the result here. Round up to the nearest whole card/container.
Document the simple pull rules for this part (e.g., 'Empty container + card goes to replenishment point; do not refill on the spot').
Describe where the card originates, how it's used for replenishment, and disposal or archiving rules. Keep it short and actionable.
Notes on how to lay out the supermarket, signage, labels, and physical separation for fast movers vs slow movers.
Record test actions, who will try this configuration, and when to review.
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