Once you have selected the scheduling signal, you need to determine the signal and material logistics. You, and your team, need to determine how material and the kanban signal will move from the production process to downstream customers. You will also need to determine how the signal will make it back to the production process.

If you have not already done so then this is the perfect time to take a fieldtrip to the production process. During this fieldtrip, walk the path of the materials. Start at the production process and follow the same path the material takes to its customer. Look for stops, staging problems, and convenient ways to move the signals. Take this opportunity to determine the who, what, and when of the process. As Figure 5-17 shows, you must create a continuous loop of material and signals flowing from the production process to the customer and back again.

Figure 5-17: The Kanban Design Must Create a Continuous Flow of Materials and Signals.

One of the first logistic decisions will be how the material will be staged or whether you need to change how you currently stage your production material. Consider how the layout facilitates maintenance of the kanban cycle when making the staging decision. Also, do you want to keep the material in one spot or dispersed to the customer cells? Consider how your organization manages material storage and stage the material where the highest kanban discipline will be maintained.

Consider the logistics...