Warehouse & Inventory · SOP

Hardware Hinges & Slides Kanban System

Implement a two-bin Kanban replenishment system for critical hardware components (hinges and drawer slides) to ensure production never pauses due to stockouts.

Estimated Time

5 days

Difficulty

Intermediate

Regulation

Internal Lean Standard

Version

1.0

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Purpose

This SOP defines a standardized two‑bin Kanban process for managing inventory of high‑usage hardware hinges and drawer slides. The system eliminates manual stock counts and ad‑hoc purchasing, reduces order lead‑time, and ensures that production lines always have available parts without holding excessive safety stock.

Scope

Applies to all hinge and drawer slide SKUs stored in the main hardware warehouse or satellite assembly kitting areas. Excludes custom‑cut or special‑finish components that require unique order processes. The procedure covers bin setup, labelling, replenishment triggers, and daily auditing for up to 200 SKUs.

Safety Precautions

LIFTBins may weigh up to 25 kg when fully stocked. Use a dolly or pallet jack when moving multiple full bins. Avoid lifting bins above shoulder height.
CUTBins constructed from steel wire or heavy plastic may have sharp edges. Inspect each bin for burrs and wear cut‑resistant gloves when handling.
FIREKeep Kanban bins away from open flames, welding stations, or high‑heat areas. Store hardware bins on grounded metal shelving.

Required Tools & Materials

Two identical Kanban bins per SKU (colour‑coded by part family: hinges blue, slides yellow)
Weather‑resistant bin labels with clear print for part number, description, min/max qty, supplier SKU, and bin location
Inventory management software (or spreadsheet) to track current bin status and trigger purchase orders
Handheld barcode scanner (recommended) for quick bin scanning
Label printer or pre‑printed laminated tags
Measuring tape or calipers to verify correct bin dimensions

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Procedure: Step-by-Step

1 Audit Current Consumption. Pull 4 weeks of usage data for each hinge and slide SKU from your WMS or manual tallies. Calculate average daily/monthly demand to set baseline quantities.

2 Define Bin Quantities. For each SKU: Minimum quantity = (average daily usage × supplier lead time in days) + safety stock (20% of lead‑time demand). Maximum quantity = 2 × minimum. Round up to nearest convenient count (e.g., 50, 100).

3 Label and Install Kanban Bins. Print labels containing: part number, description, min/max, supplier SKU, bin location (aisle‑rack‑shelf). Place two bins per SKU in the picking area. Ensure first bin is in the primary picking position, second bin directly behind it.

4 Establish the Replenishment Trigger. The rule: When the first bin is emptied, move it to the replenishment lane. The second bin becomes the active picking bin. Empty bins are never placed back in the picking position until refilled.

5 Replenish Empty Bins. Each morning (or at a scheduled interval), scan or collect all bins in the replenishment lane. For each empty bin, generate a purchase order to the pre‑approved supplier for the exact quantity needed to fill that bin (typically one lot equal to the maximum quantity). Attach the label to the new stock.

6 Return and Rotate. When replenished stock arrives, place the full bin behind the currently active bin in the picking area. This ensures first‑in, first‑out (FIFO) rotation and prevents expiry of older stock.

7 Audit and Adjust. Once per month, review bin velocity and adjust min/max quantities if demand has shifted. Check for dead stock or overstock. Update labels accordingly.

Hardware Hinges & Slides Kanban System

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