Kanbans at Toyota

Reynald Debaut-Henocque explains the use of Kanbans at TMMF


Kanbans are used in production systems based on pull flows: Demand from the downstream process triggers the production of upstream processes. They prevent the emergence of problems related to high level of stocks. They can be applied in two areas: to manage the flows between a factory and its external suppliers and the flows within the factory, between workshops and machines. Kanban loops needs to be revised (size, number of cards) continuously depending on the course of production volumes. Ex-vice-president of manufacturing at Toyota Motor Manufacturing (TMMF), Reynald reckons production control with kanbans is no longer a source of difficulty in Toyota factories. Indeed, as they had been invented for the first pull systems at the very beginning of the Lean movement, their application has become today systematic, mecanical.


Video available in French only, English version coming soon!



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Marris Consulting is an expert in the Theory of Constraints (ToC) and Critical Chain Project Management (CCPM). As industry consultants, we are focused on helping process and manufacturing industries reach their highest levels of performance by using Constraints Management  combined with Lean and Six Sigma. We also use Critical Chain Project Management which we sometimes combine with Lean engineering to improve project performance. If you are unsure about the actions which need to be implemented to improve operational efficiency, our industrial management consultants can also conduct a performance audit. Furthermore, our experts host numerous Theory of Constraints (ToC), lean and project management training sessions throughout the year.

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Marris Consulting is an industry consulting and training company specialized in the Theory of Constraints (ToC) and Critical Chain Project Management. We focus on improving the performance of manufacturing and process industries by using Constraints Management combined with Lean and Six Sigma. To boost project performance, we also use Critical Chain Project Management (CCPM), which we sometimes combine with Lean Engineering. Our 2-day performance audits, our performance consulting services and our project management, Lean, ToC & CCPM training by our industry consultants offer a wide range of solutions to help our clients around the world reach the highest possible levels of performance.

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