Kanban Card Generator

Generate print-ready kanban reorder cards with barcodes, QR codes, and color-coded headers. Download as PNG or tiled PDF with die lines for cutting.

Card Preview

What Is a Kanban Card?

A kanban card is a visual signal used in lean manufacturing and inventory management to trigger replenishment. The word kanban (看板) is Japanese for "signboard." In a pull-based system, material is only ordered when downstream consumption creates demand — and the kanban card is the physical mechanism that carries that signal from the point of use back to the supplier or stockroom.

How a Two-Bin Kanban System Works

The simplest kanban implementation is the two-bin system. Each part has two bins at the point of use: an active bin and a reserve. When the active bin empties, the operator pulls the kanban card from the bin and sends it to purchasing (or directly to the supplier). The reserve bin keeps production running while the order is fulfilled. Once the replenishment arrives, the reserve becomes active and the cycle repeats.

The card itself encodes everything needed to reorder: part number, supplier, order quantity, bin location, and often a barcode or QR code for scanning into an ERP or inventory system.

Setting Reorder Points and Quantities

The reorder point (ROP) is the inventory level that triggers a new order. It accounts for lead time demand plus safety stock: ROP = (daily usage × lead time) + safety stock. The order quantity is typically the economic order quantity (EOQ) or a supplier-required minimum. Getting these numbers right is the difference between stockouts and excess inventory — and the reason many teams pair kanban cards with statistical process control to track consumption variability.

Physical Card Sizes

This generator supports three standard sizes used in industry:

Barcodes and QR Codes on Kanban Cards

Modern kanban cards carry Code128 barcodes for rapid scanning at receiving and cycle-count stations, plus optional QR codes that encode either a reorder URL (scan-to-order) or the full card data as JSON for integration with WMS, ERP, or spreadsheet-based inventory systems. This generator produces both at 300 DPI, ensuring crisp output whether printed on card stock, adhesive labels, or laminated for reuse.

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Frequently Asked Questions

What is a kanban reorder card?
A kanban reorder card is a visual signal used in lean manufacturing and inventory management. When stock in a bin drops to the reorder point, the card is pulled and sent to purchasing or the supplier to trigger a replenishment order. Each card typically shows the part number, supplier, reorder quantity, and a barcode for scanning.
What card sizes are supported?
Three standard sizes: CR80 (3.375 x 2.125 in) for badge-size cards and card sleeves, Half-Letter (3.5 x 5.5 in) for standard kanban cards and bin labels, and Index 4x6 (4 x 6 in) for large kanban cards and wall displays. All render at 300 DPI for sharp print quality.
Can I generate multiple cards at once?
Yes. Use the Batch Entry tab to fill in a spreadsheet-style table, or the Import tab to paste JSON or CSV data from a spreadsheet export. Cards are tiled onto US Letter pages in the PDF output with die lines for cutting.
What barcode format is used?
Code128 — the most common alphanumeric barcode format in inventory systems. It encodes the supplier SKU (if provided) or the internal part number. Supported by virtually every handheld scanner and phone camera.
What does the QR code encode?
Two options: the URL/Phone QR encodes a reorder URL or phone number for quick scan-to-order, and the Data QR encodes the full card data as JSON (part number, location, supplier, quantities) for integration with inventory systems.
How do the PDF die lines work?
PDF output tiles multiple cards per US Letter page (8 CR80 cards, 2 half-letter, or 1 index per page) with cut marks drawn from the page edges to the card boundaries. Use a paper slicer or guillotine cutter aligned to these marks.