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Kanban Sandan (三段) — Grade 3 Certification Exam Study Guide
This study guide prepares you for the Kanban Sandan (Grade 3) Certification by covering advanced topics including process policy development, TPS integration, and key performance metrics. You will explore leadership strategies, visual management techniques, and the practical application of Kaizen to drive continuous improvement within your teams.
MODULE 1 — New Module
The development and customization of explicit process policies are essential for establishing clear guidelines and expectations in Kanban systems, ensuring consistency and efficiency.
Integrating these policies with the Toyota Production System (TPS) pillars enhances overall process efficiency and supports the fundamental principles of lean management.
Advanced feedback loops are critical in traditional settings; they enable continuous assessment and adaptation of processes, fostering a culture of ongoing improvement.
Key metrics in Kanban include cycle time, lead time, and throughput, which allow teams to quantitatively assess performance and identify bottlenecks in workflows.
Mastering Kanban tools involves understanding their functionalities and how they can facilitate communication and collaboration among team members.
Visual management techniques, such as flow charts and Kanban boards, help convey process information clearly and should be standardized across teams for effective scaling.
As a Kanban leader, it is crucial to embody roles of coaching and mentoring, ensuring that team members are empowered and that their contributions are respected.
Kaizen, or continuous improvement, requires active involvement from all team members to identify issues and experiment with solutions systematically.
| Concept | Formula | Purpose |
|---|---|---|
| Cycle Time | Cycle Time = Total Time / Number of Completed Units | To evaluate the average time taken to complete a unit from start to finish. |
| Lead Time | Lead Time = Time of Order to Delivery | To measure the total time taken from the moment a customer places an order until it is fulfilled. |
| Throughput | Throughput = Number of Units Completed / Time Period | To assess the productivity of a team or process over a specified timeframe. |
Test your knowledge with these 10 practice questions. Select your answers and submit to see your score.
Which of the following is NOT listed as a key TPS metric used to support data-driven adjustments within Traditional Kanban feedback loops, according to the Kanban Sandan Certification Manual?
According to the Kanban Sandan Certification Manual, Cycle Time — defined as the time to complete one full Kanban loop — is listed as one of the key traditional TPS metrics used to support data-driven adjustments in feedback loops.
In the Traditional Kanban system at the Sandan level, 'Tool Champions' are senior managers responsible for setting policy direction across all locations, rather than local experts maintaining Kanban tool integrity at their specific site.
Match the feedback loop type to its correct description as defined in the Kanban Sandan Certification Manual.
What does the term 'Genchi Genbutsu' mean and how is it applied in the Kanban Sandan context?
Match the Kanban leadership role to its correct description as defined at the Sandan level.
Why are non-compliance findings during policy audits treated as Kaizen opportunities rather than punitive events at the Sandan level?
Match the Sandan-level leadership role to its correct description as defined in the Kanban Sandan Certification Manual.
What is the recommended frequency for feedback loops monitoring fast-moving items in a Traditional Kanban system?
At the Sandan level, congestion in specific columns of a Kanban Board is interpreted as a signal of bottlenecks, imbalances (Mura), or overburden (Muri) within the system.