Kanban vs Kaizen: How Lean Tools Drive Manufacturing Excellence
- 77 Teknik
- Jul 30
- 4 min read
Updated: 5 days ago
Applying Lean Thinking to Production at 77 Teknik
In precision manufacturing, efficiency is everything. That’s why lean principles such as Kanban and Kaizen have become essential tools in modern production environments. But while both support continuous improvement, they serve different purposes and offer distinct advantages.
At 77 Teknik, we apply both Kanban and Kaizen strategically to streamline workflows in productions
What is Kanban?
Kanban is a visual workflow management method designed to improve efficiency and eliminate waste in production and business processes. Originally developed by Toyota in Japan, the term "Kanban" means "visual sign" or "card" in Japanese.
At its core, Kanban helps teams visualize their work by using a board (known as a Kanban board) divided into columns such as “To Do,” “In Progress,” and “Done.” Each task is represented by a card that moves through the columns as work progresses. This allows teams to clearly see the status of each task at any given time.
Core Principles of Kanban:
Visualize the Workflow: Make all work visible by representing tasks as cards on a board. This helps identify bottlenecks and manage workload more effectively.
Limit Work in Progress (WIP): By setting limits on how many tasks can be in progress at once, teams can focus better and reduce multitasking.
Manage Flow: Ensure work items move smoothly and continuously through the workflow, minimizing delays and interruptions.
Continuous Improvement: Kanban encourages regular analysis and optimization of processes to improve efficiency and reduce waste.
Where is Kanban Used?
While Kanban originated in manufacturing, it is now widely used in various industries, including software development, engineering, marketing, and personal productivity. It is especially popular in Agile environments, offering teams a flexible and transparent way to manage projects.
Key Benefits of Kanban:
Improves transparency across teams and workflows
Enhances collaboration and communication
Quickly highlights bottlenecks and delays
Reduces waste and optimizes resource use
Encourages ongoing process improvement
Applications at 77 Teknik:
Tool and fixture inventory for CNC cells
Sheet metal raw material stock levels
WIP (Work in Progress) limits in welding bays
Visual Kanban boards in production areas
Example:In our CNC milling department, Kanban cards automatically trigger tool replenishment when usage reaches a defined threshold minimizing downtime and improving throughput.
What is Kaizen?
Kaizen is a Japanese philosophy that means “continuous improvement.” Rooted in post-World War II Japanese manufacturing practices, Kaizen focuses on making small, incremental changes that collectively lead to significant long-term improvements in productivity, efficiency, and quality.
Unlike large-scale overhauls, Kaizen emphasizes daily, ongoing progress encouraging all employees, from top management to shop floor workers, to actively contribute to process improvements.
Core Principles of Kaizen:
Continuous Improvement: Every process can be improved, no matter how efficient it seems today. Kaizen encourages a culture of ongoing optimization.
Employee Involvement: Team members are empowered to identify problems and suggest practical solutions. Their insights are key to driving change.
Standardization: Once improvements are made, new processes are standardized to maintain consistency and build a foundation for future progress.
Elimination of Waste (Muda): Kaizen seeks to reduce or eliminate activities that don’t add value such as unnecessary motion, overproduction, or idle time.
Where is Kaizen Used?
Originally developed in manufacturing — particularly within Toyota’s production system — Kaizen is now widely applied in sectors such as healthcare, logistics, software development, service industries, and even personal productivity.
It complements other lean manufacturing and agile methodologies by fostering a mindset of efficiency and accountability at all levels.
Key Benefits of Kaizen:
Fosters a proactive and improvement-driven company culture
Enhances team morale and employee engagement
Reduces waste and increases operational efficiency
Improves product and service quality
Strengthens long-term competitiveness and innovation
Applications at 77 Teknik:
Weekly Kaizen events to reduce setup time
Operator-led suggestions for process improvements
Data-driven defect reduction initiatives
5S and safety improvement audits in welding cells
Example:One Kaizen event led to a 15% reduction in tool changeover time on our 5-axis CNC machines, boosting daily output without additional labor.
Kanban vs Kaizen: Key Differences
Feature | Kanban | Kaizen |
Purpose | Visual workflow management | Continuous improvement methodology |
Focus | Workload balance & material control | Process optimization & defect reduction |
Scope | Operations, inventory, scheduling | Company-wide (culture + systems) |
Implementation | Through boards/cards & pull systems | Through team-based events & feedback |
Benefit | Improves production flow | Reduces inefficiencies & waste |
Why We Use Both at 77 Teknik
We don’t choose between Kanban vs Kaizen we integrate them:
Kanban ensures production stability
Kaizen ensures continuous performance improvement
Together, they help us reduce downtime, improve lead times, and deliver high-precision parts that meet strict quality requirements in automotive, defense, and aerospace projects.
Both Kanban and Kaizen are powerful lean tools but they’re even more effective when used together. At 77 Teknik, we implement them to enhance flexibility, reduce waste, and increase precision in every production run.
Optimize Your Production with Lean Experts
Looking to implement lean manufacturing strategies in your supply chain? Let 77 Teknik help streamline your CNC, welding, and sheet metal part sourcing.
Contact us today for a lean-driven production partnership.