Which signaling method is often referred to as the signaling system used in Toyota's production, characterized by cards or signals?

• A. Kaizen
• B. Lean production
• C. Level production method
• D. Kanban

Answer: (D)

Kanban is the signaling method used in Toyota's production system that relies on cards or signals to trigger replenishment and movement of parts. It operates as a pull system: a downstream station signals upstream to produce only what is needed, when it’s needed, and in the right quantity. This visual signaling helps limit work in process and keeps the flow smooth. A Kanban card attached to a container represents permission to move or produce a given amount, and when the downstream area consumes items, the card is returned to trigger the next replenishment. This signaling mechanism is a defining feature of Toyota’s approach and is distinct from broader ideas like Kaizen (continuous improvement), Lean as a whole, or level production, which focuses on smoothing output rather than signaling.