Once Emca Golf's kanban kaizen team understands the basic principles of kanban and has completed all the necessary kanban pull systems preparation work we discussed in the previous sections, they can begin the process of determining the number of kanban needed to effectively link head machining and assembly.

To start out, the team must identify all of the golf club heads that are produced in head machining. The kaizen team identified the following part numbers:

We can see from the above table that head machining is a shared resource that produces a variety of 16 different heads for club assembly.

Having identified the 16 part numbers that will be placed under kanban control, the kaizen team will need to quantify the amount of daily demand each head model places on head machining in order to satisfy the needs of its internal customer assembly. This is called performing a requirements study and the tool we use is called the Requirements Study Worksheet.