Template · Industrial engineering
Kanban container and card calculator
Size a pull replenishment loop by calculating lead-time demand, safety-buffered demand, and required kanban containers.
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XLSXCSVODSXMLNumbers| Kanban container and card calculator | |||||||||
| Example data — replace the blue input cells with your own. | |||||||||
| Size a pull replenishment loop by calculating lead-time demand, safety-buffered demand, and required kanban containers. | |||||||||
| Populated records | 6 | Prepared capacity used | 10.0% | ||||||
| Total kanban cards | 28 | Peak: Kanban cards | 5 | ||||||
| Average: Kanban cards | 5 | ||||||||
| Active rows bar | ██ | ||||||||
| 60 record rows (6 sample rows shown). Blue cells are inputs; dark cells calculate. | |||||||||
| Part / loop | Daily demand units | Shift hours per day | Lead time hours | Safety factor | Container size units | Lead time demand | Buffered demand | Kanban cards | Scale bar |
| Bracket P-10 | 480.0000 | 16.0000 | 4.0000 | 25.0% | 30 | 120.0000 | 150.0000 | 5 | ████████████ |
| Housing P-20 | 320.0000 | 16.0000 | 6.0000 | 20.0% | 40 | 120.0000 | 144.0000 | 4 | ██████████ |
| Fastener kit P-30 | 800.0000 | 16.0000 | 8.0000 | 15.0% | 100 | 400.0000 | 460.0000 | 5 | ████████████ |
| Bracket P-10 (4) | 720.0000 | 24.0000 | 6.0000 | 25.0% | 45 | 180.0000 | 225.0000 | 5 | ████████████ |
| Housing P-20 (5) | 256.0000 | 12.8000 | 4.8000 | 20.0% | 32 | 96.0000 | 115.2000 | 4 | ██████████ |
| Fastener kit P-30 (6) | 1,000.0000 | 20.0000 | 10.0000 | 15.0% | 125 | 500.0000 | 575.0000 | 5 | ████████████ |
Showing the first 16 of 72 rows and 10 of 10 columns. Cells with formulas show the formula on hover.
| Kanban container and card calculator |
| Method, inputs, and limits for this workbook. |
| What it does |
| Size a pull replenishment loop by calculating lead-time demand, safety-buffered demand, and required kanban containers. |
| How to use it |
| Replace the fictional records in blue cells with your own data. Keep the dark formula cells. Use the units stated in the column headers and keep each record on one row. Read the calculated columns and inspect the results before using them.… |
| Formulas and method |
| Lead-time demand divides daily demand by shift hours per day and multiplies by replenishment lead time in hours. Buffered demand applies the safety factor, and kanban cards rounds buffered demand divided by container size up to a whole con… |
| Assumptions and limits |
| Assumes steady daily demand and replenishment times expressed on the same operating-hour basis. Large lot-sizing or transport batch constraints must be checked separately. |
| Missing numeric inputs |
Showing the first 16 of 72 rows and 4 of 4 columns. Cells with formulas show the formula on hover.
What does this template do?
Size a pull replenishment loop by calculating lead-time demand, safety-buffered demand, and required kanban containers.
Lead-time demand divides daily demand by shift hours per day and multiplies by replenishment lead time in hours. Buffered demand applies the safety factor, and kanban cards rounds buffered demand divided by container size up to a whole container.
Assumes steady daily demand and replenishment times expressed on the same operating-hour basis. Large lot-sizing or transport batch constraints must be checked separately.
The working tab keeps editable inputs separate from formulas, with 6 populated sample rows, summary KPIs, an in-cell scale bar, and room for 60 records. The Notes tab explains the method and how to extend the range. All example records are fictional and can be replaced. Download a workbook format to retain formulas, or CSV when you need calculated values only.
What’s inside
- Lead-time demand divides daily demand by shift hours per day and multiplies by replenishment lead time in hours. Buffered demand applies the safety factor, and kanban cards rounds buffered demand divided by container size up to a whole container.
- 60 prepared record rows with blank-row guards and in-cell scale bars
- Summary KPI block with peak, average, and capacity tracking
- Blue input cells, typed dates and numbers, and frozen column headers
- Notes with the method, assumptions, and range-extension instructions
Which tabs does the workbook have?
| Tab | What it holds |
|---|---|
| Worksheet | Size a pull replenishment loop by calculating lead-time demand, safety-buffered demand, and required kanban containers. |
| Notes | How to use the workbook, formula method, assumptions, and file format limits. |
What formulas does this template use?
This template holds 246 formulas in 320 cells across 2 tabs, so 77% of its cells calculate. They use 14 distinct functions; the longest formula is 134 characters.
| Function | Uses | What it does |
|---|---|---|
IF | 664 | one result when a test is true, another when false |
COUNT | 182 | counts numeric cells |
MAX | 182 | largest value |
OR | 180 | true when any test is true |
MIN | 61 | smallest value |
REPT | 61 | repeats text |
ROUND | 61 | rounds to a number of digits |
ISNUMBER | 60 | true for a number |
NOT | 60 | reverses true and false |
ROUNDUP | 60 | rounds away from zero |
COUNTA | 4 | counts non-empty cells |
COUNTIF | 2 | counts cells meeting one condition |
The 12 most used of 14 functions. Counted from the workbook itself. Only functions that Excel, LibreOffice Calc, Google Sheets and Apple Numbers evaluate the same way are used, so the formulas survive every download format.
How do you use it?
- Replace the fictional records in blue cells with your own data. Keep the dark formula cells.
- Use the units stated in the column headers and keep each record on one row.
- Read the calculated columns and inspect the results before using them. Clear unused input rows; keep their formulas.
- The prepared range holds 60 records in rows 11–70. Extend formulas and summary ranges together if you add more rows.
What is it good for?
- Size a pull replenishment loop by calculating lead-time demand, safety-buffered demand, and required kanban containers
- Replacing the labeled fictional records with your own figures
- Checking a calculation before adapting it to a larger workbook
Questions about this sheet
How is the result calculated?
Lead-time demand divides daily demand by shift hours per day and multiplies by replenishment lead time in hours. Buffered demand applies the safety factor, and kanban cards rounds buffered demand divided by container size up to a whole container.
What assumptions should I check?
Assumes steady daily demand and replenishment times expressed on the same operating-hour basis. Large lot-sizing or transport batch constraints must be checked separately.
Can I add more than 60 records?
Yes. Copy the formula columns into new rows and extend every summary range to include them. Keep inputs and formulas in their original columns.
Are the example records real?
No. All example data is fictional and intended to demonstrate the formulas. Replace it before using the workbook for your own work.