Build a Practical Physical Kanban System

The Accessible Lean Consulting Kanban Starter Kit is a complete, ready-to-deploy physical Kanban solution designed specifically for Australian manufacturers, workshops, maintenance teams, warehouses and production environments.

Unlike software-based systems that require extensive setup and ongoing administration, this kit provides a highly visual, simple and scalable method for controlling inventory, triggering replenishment and improving production flow directly on the factory floor.

Whether you're implementing Kanban for the first time or expanding an existing Lean system, this kit provides everything required to establish clear reorder points, production triggers and visual inventory management standards.

Designed to Help You:

✔ Reduce stock shortages and production interruptions
✔ Improve inventory visibility
✔ Standardise replenishment processes
✔ Reduce excess inventory holdings
✔ Create clear production priorities
✔ Support continuous improvement initiatives
✔ Improve communication between purchasing, stores and production teams
✔ Build a practical Lean manufacturing culture

What's Included

Inventory Storage System

• 48 × Small Blue Containers with Dividers

• 48 × Medium Blue Containers with Dividers

• 24 × Large Blue Containers with Dividers

The included containers create the foundation of a practical two-bin Kanban system. Each container includes a divider to separate active stock from replenishment stock, making inventory levels instantly visible to operators.

Visual Kanban Trigger System

• 2 × Kanban Reorder Point Holders

• 2 × Kanban Production Point Holders

• 150 × Kanban Cards

  • Purchase Kanban Cards

  • Production Kanban Cards

The Kanban holders provide a dedicated location for active replenishment signals, ensuring purchasing and production teams always know what action is required.

Label & Identification System

• 2 × DYMO LabelWriter 550 Printers

• 4 × Packs DYMO Industrial Labels

• USB containing editable label templates

• 150x Ready to Use Magnets

Create professional part labels, location labels and Kanban cards quickly and consistently.

Digital Data Collection Tools

• Barcode Scanner

• Digital Camera

Capture inventory information, part data and visual standards with ease.

Implementation Resources

• Physical Kanban System Guide

• Setup Templates

• Implementation Instructions

A practical step-by-step guide showing exactly how to establish locations, create Kanban cards, set reorder quantities and launch a visual replenishment system.

Why Accessible Lean Consulting?

This kit has been developed from real-world manufacturing experience and is designed to help businesses create sustainable improvements without expensive software subscriptions or complicated ERP integrations. Many customers begin with a pilot area before gradually rolling out Kanban across production, maintenance stores, warehouses and spare parts inventory. This kit has been designed to support that journey, allowing you to scale at your own pace without needing to replace your original setup.

Whether you're managing 100 part numbers or 10,000, the Accessible Lean Consulting Kanban System is designed to grow with your operation.

Simple. Visual. Flexible. Scalable.

Create a simple, visual replenishment system that is easy to understand and easy to maintain.

Accessible Lean Consulting Kanban Cards are designed to provide a clear trigger for replenishment, helping teams know exactly when to order purchased items or manufacture internally produced components. Available in both Purchase and Production versions, these cards form the foundation of a practical Kanban system that can be implemented in workshops, warehouses, factories, and manufacturing environments of any size.

Each card features a dedicated area designed to suit standard DYMO 101mm x 54mm Shipping Labels, allowing part information, descriptions, locations, quantities, barcodes, and supplier details to be printed and applied quickly using a DYMO label printer.

When stock reaches its trigger point, the card is removed and placed into a Kanban Reorder Point Holder or Production Point Holder. The reverse side of the card is then used to indicate the current status:

• Purchase Cards: "Part On Order"

• Production Cards: "Production Required"

This simple visual status system allows everyone on the floor to immediately understand where replenishment requests are up to without needing spreadsheets, software, or complex tracking systems.

Manufactured from high-quality card stock suitable for industrial environments, these cards are designed for daily handling while remaining lightweight, practical, and cost-effective.

Features

• Creates a clear visual trigger for replenishment

• Compatible with DYMO 101mm x 54mm Shipping Labels

• Dedicated space for part information and identification

• Double-sided design with replenishment status indicators

• Simple visual management system

• Supports Lean manufacturing and Kanban workflows

• High-quality card stock suitable for industrial environments

Simple, visual, and effective. Kanban Cards help create reliable replenishment signals, reduce stockouts, and make inventory management easier for everyone on the floor. Practical Strategies. Real Results.

Create a simple visual production signal without the complexity of a scheduling system.

The Kanban Production Point Holder is designed to act as a visual "To Do List" for production areas, providing a clear location for Kanban Production Cards to accumulate as demand is generated from downstream processes.

Unlike traditional production scheduling systems, this holder does not attempt to sequence work, allocate resources, or manage production priorities. Instead, it creates a simple and highly visible signal that production is required. This makes it ideal for supporting Lean manufacturing environments where simplicity, visibility, and flow are prioritised over complex planning systems.

As Kanban cards enter the holder, they authorise production and then production station owner can visually schedule the production. It is the responsibility of the production area to review the cards, manufacture the required items, and return completed cards back into the Kanban system.

The Kanban Production Point Holder works particularly well in environments where multiple products flow through shared work centres, helping bridge the gap between inventory replenishment systems and day-to-day production activities.

Features

• Creates a simple visual production "To Do List"

• Provides a dedicated collection point for Kanban Production Cards

• Supports Lean manufacturing and pull-based production systems

• Helps improve visibility of production demand

• Durable clear acrylic construction

• Easy to install in production areas and work centres

Ideal For

• Fabrication departments

• CNC machining areas

• Welding stations

• Assembly work centres

• Manufacturing cells

• Maintenance workshops

Best Used With

• Accessible Lean Consulting Production Kanban Cards

• Kanban Reorder Point Holders

• Two-Bin Inventory Systems

• Visual Management Boards

• Lean Manufacturing Workflows

Important Note

The Kanban Production Point Holder is not a production scheduling system. It is a visual production signal designed to support flow between inventory replenishment systems and manufacturing operations. Cards placed in the holder authorise production, while the production station owner or team leader remains responsible for prioritising, distributing, and manufacturing the required work.

Simple. Visual. Effective. Helping production teams maintain flow without unnecessary complexity.

Create a clear and visible trigger for replenishment with the Kanban Reorder Point Holder.

Designed to work alongside Accessible Lean Consulting Kanban Cards, this holder provides a dedicated location for reorder signals, ensuring inventory replenishment requests are visible, organised, and impossible to miss. When a Kanban card reaches the holder, it signals that stock has reached its minimum quantity and action is required.

Manufactured from durable clear acrylic, the holder can be mounted in production areas, storerooms, warehouses, and workshops to provide a central collection point for replenishment signals.

Features

• Provides a dedicated location for Kanban reorder cards

• Creates a clear visual signal when stock reaches minimum levels

• Supports Lean inventory management and material flow

• Durable clear acrylic construction

• Suitable for factories, workshops, warehouses, and storerooms

• Easy to integrate into existing Kanban systems

Best Used With

• Accessible Lean Consulting Kanban Cards

• Kanban Starter Kits

• Two-Bin Replenishment Systems

• Production Kanban Systems

• Visual Management Boards

For best results, use as part of a complete Kanban system with Kanban Cards. The holder provides the collection point, while the cards provide the replenishment signal. Together they create a simple, visual system that keeps inventory flowing and production moving.

Create a dedicated, professional Red Tag Area that drives accountability, workplace organisation, and Lean discipline on the factory floor.

Designed for manufacturers serious about implementing practical 5S systems, the Red Tag Area Shelf Kit provides a complete visual management solution in one premium package. Built around a heavy duty industrial shelving system, this setup creates a clear, highly visible quarantine area for unused, damaged, obsolete, or questionable items during workplace organisation and continuous improvement activities.

The shelving system measures 2.4 metres high by 2 metres wide and features industrial shelving rated to 250kg per shelf level, making it suitable for real manufacturing environments and daily operational use.

Every component has been selected to help businesses implement a clean, professional, and easy-to-maintain Red Tag process without the hassle of sourcing parts individually. The result is a factory-ready visual management station that looks professional, reinforces Lean culture, and encourages consistent workplace standards.

The shelving cross members require painting during assembly to achieve the finished Red Tag appearance shown in the product images. This process is straightforward and designed to be completed easily during setup.

Features

• Heavy duty industrial shelving system

• Factory-ready Red Tag Area presentation

• Professional visual management solution

• Supports 5S and workplace organisation initiatives

• Designed for real manufacturing environments

• Easy assembly and installation

• Premium branded appearance

• Highly visible Red Tag containment zone

Ideal For

• Manufacturing facilities

• Warehouses

• Maintenance workshops

• Production environments

• Continuous improvement programs

• 5S implementations

• Lean transformation projects

Please Note: Product photos are representations of the final assembled setup. Minor variations may occur depending on assembly and installation conditions.

Shipping Information

Due to this product being supplied through multiple specialist suppliers and components being carefully consolidated prior to dispatch, shipping times may be longer than our standard delivery estimates. This allows us to maintain product quality and ensure all components arrive ready for installation.

A professional visual management sign designed to clearly identify red tag holding zones within manufacturing and warehouse environments. The Red Tag Area Aluminium Sign helps support 5S workplace organisation by creating a visible and standardised location for tagged items during sorting and improvement activities.

Manufactured using coated white aluminium composite material, this sign provides a clean modern appearance while remaining lightweight, rigid, and durable for industrial environments.

Ideal for production areas, workshops, warehouses, maintenance departments, and Lean improvement zones.

Features:

• Coated white aluminium composite construction
• Clean high visibility industrial design
• Suitable for indoor and sheltered outdoor use
• Lightweight, rigid, and durable
• Fade resistant professional print finish
• Designed for manufacturing and warehouse environments
• Supports 5S and Lean visual management systems

Perfect for businesses looking to improve workplace organisation and create clear visual standards throughout the factory floor.

A practical visual management solution designed to support stronger Lean culture and workplace organisation.

A complete Lean culture poster pack designed to bring continuous improvement, workplace organisation, and problem solving to the factory floor. The Moving Australia Forward Vision Board Pack includes four professionally designed foam board visuals that can be displayed together as a connected Lean improvement wall or used individually throughout different areas of your workplace.

Printed on quality paper and mounted to lightweight foam board, these boards are ideal for production areas, workshops, warehouses, offices, training rooms, and continuous improvement spaces.

Each design focuses on practical manufacturing principles with clear visual communication that helps reinforce Lean thinking in day to day operations.

Included in the pack:

• DOWNTIMES Lean Waste Board

• 5S Best Practices Board

• Root Cause Analysis Board

• Moving Australia Forward Vision Board

Features:

• Designed for manufacturing environments

• Can be displayed together or separately

• High visibility Lean culture visuals

• Supports training and continuous improvement initiatives

• Consistent Accessible Lean Consulting branding across the full set

Perfect for businesses looking to create a stronger improvement culture while keeping Lean concepts visible and easy to engage with on the floor.

A practical visual system designed to help move teams, culture, and Australian manufacturing forward.

A practical Lean improvement visual designed to encourage problem solving, critical thinking, and continuous improvement on the factory floor. The Root Cause Analysis Vision Board promotes the mindset that every issue is an opportunity to improve processes, systems, and workplace performance.

Printed on quality paper and mounted to a lightweight foam board, this board is ideal for production areas, improvement boards, meeting rooms, and Lean training environments.

Built around simple visual communication, the design reinforces key continuous improvement concepts including the 5 Whys method, root cause thinking, rapid learning, and problem solving culture.

Features:

• Reinforces Root Cause Analysis and 5 Whys thinking

• High visibility motivational design

• Supports Lean and continuous improvement culture

• Ideal for workshops, factories, and training areas

• Encourages teams to solve problems instead of hiding them

A practical visual reminder that solving problems creates stronger systems, better workflows, and continuous improvement across the workplace.

A visual workplace guide designed to reinforce practical 5S standards across manufacturing and warehouse environments. The 5S Best Practices Board uses real world visual examples to help teams quickly identify what organised, efficient, and standardised work areas should look like.

Printed on quality paper and mounted to a lightweight foam board, this board is ideal for production floors, workshops, warehouses, maintenance areas, and Lean training spaces.

The layout focuses on simple visual communication, making it easy for workers and supervisors to reference key workplace organisation standards during daily operations.

Features:

• Visual examples of practical 5S standards

• Easy to understand workplace guidance

• Supports Lean and continuous improvement initiatives

• Suitable for factories, workshops, and warehouses

• High visibility design for production environments

A practical visual reminder that small changes create safer, cleaner, and more efficient workplaces.

A motivational workplace visual designed to reinforce positive Lean culture and continuous improvement on the factory floor. The Moving Australia Forward Vision Board focuses on practical manufacturing values including teamwork, daily improvement, and creating value for customers.

Printed on quality paper and mounted to a lightweight foam board, this board is ideal for production areas, offices, lunchrooms, training spaces, and improvement zones where culture and direction matter.

Built around Accessible Lean Consulting branding, the design combines strong messaging with clean visuals to help create a workplace environment focused on growth, accountability, and improvement.

Features:

• Motivational manufacturing focused design

• Reinforces Lean culture and workplace values

• Clear, high visibility layout

• Suitable for factories, workshops, and offices

• Encourages continuous improvement thinking

A simple visual reminder that strong manufacturing culture starts with the people on the floor.

A practical visual guide designed to support 5S and workplace organisation activities on the factory floor. The Red Tag Process Sheet Board helps workers and supervisors quickly understand what should be kept, tagged, repaired, stored, recycled, or removed during a Red Tag process.

Printed on quality paper and mounted to a lightweight foam board, this board is ideal for production areas, warehouses, maintenance workshops, and Lean improvement zones.

The layout separates responsibilities between workers and supervisors, making the process easier to follow while encouraging consistent decision making across the workplace.

Features:

• Clear worker and supervisor guidance

• Supports 5S and Red Tag activities

• Easy to read visual layout with icons

• Ideal for manufacturing and warehouse environments

• Helps standardize workplace organisation decisions

A simple visual tool that encourages teams to take action, remove unnecessary items, and create safer, more organized work areas.

A simple but impactful visual tool designed to keep Lean thinking front of mind on the factory floor. The DOWNTIMES Lean Waste Awareness Board highlights the 9 common forms of waste found in manufacturing and encourages teams to challenge inefficient habits every day.

Printed on quality paper and mounted to a lightweight foam board, this board is ideal for workshops, production areas, meeting spaces, training rooms, and continuous improvement zones.

Designed using Accessible Lean Consulting branding, the layout focuses on clear visuals and fast recognition so workers and leaders can quickly connect Lean concepts to real day to day activities on the floor.

Features:

• Clean, high visibility design

• Covers the 9 DOWNTIMES wastes

• Great for Lean training and workplace awareness

• Easy to mount in production areas or offices

• Designed for practical manufacturing environments

A simple visual reminder that continuous improvement starts with identifying waste.

Make workplace organisation simple, visible, and easy to sustain.

This complete 5S Red Tag Station includes a wall-mounted red tag holder and 50 professionally designed red tags, giving your team a dedicated location to quickly identify unnecessary items, defects, waste, or improvement opportunities on the factory floor.

Designed specifically for real manufacturing environments, the tags focus on simplicity over paperwork. Large writing areas and quick checkbox selections allow operators to use them in seconds without slowing production down.

The clear wall-mounted holder keeps tags highly visible and easily accessible, helping encourage consistent use during 5S activities, clean-up campaigns, audits, and continuous improvement initiatives.

What’s Included

• 1 x Wall-mounted Red Tag Holder

• 50 x Double-sided 5S Red Tags

• Simple visual labelling system

• Ready to install and use

Why These Work

• Removes complexity from traditional red tagging

• Large writing spaces for fast identification

• Minimal text and simple checkbox design

• Encourages operator participation

• Creates a visible and professional 5S system

• Helps standardise workplace organisation

• Designed for busy production environments

A simple system is far more likely to be used consistently and consistency is what drives lasting workplace improvement.

Practical Lean Solutions. Real Results.

Most red tag systems fail because they’re too complicated.
Too many boxes. Too much writing. Too much time wasted.

These 5S Red Tags were designed to remove the complexity from workplace organisation and make red tagging fast, clear, and easy for busy production environments.

Built with a clean layout and minimal writing requirements, operators can identify issues in seconds without stopping workflow. Large writing areas allow quick identification of items while simple checkbox selections eliminate unnecessary paperwork and confusion.

The double-sided design also gives supervisors a dedicated action section, making follow-up decisions clear and visible without needing additional forms or discussions.

Perfect for:

• 5S implementations

• Factory clean-up campaigns

• Lean manufacturing rollouts

• Warehouse organisation

• Continuous improvement activities

• Red tag holding areas

These tags help teams focus on action instead of paperwork making workplace organisation easier to sustain and far more likely to succeed.

Practical Lean Solutions. Real Results.