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Production Line Automation

Jidoka Kanban by Share IT Smart

Autonomous Line Supply

Hardware-software integrated system that autonomises production line material supply. Eliminate paper kanban, prevent line stoppages, and achieve full material traceability.

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See Features
57%
Inventory Reduction
91.2%
Fewer Line Stoppages
0
Paper Documents
<3
Months ROI
Discover How It Works

Jidoka Kanban is an autonomous line supply system for production lines, built by Share IT Smart (Arad, Romania).

Jidoka Kanban is not a task-board tool like Trello or Kanban Zone, and it is not affiliated with Jidoka Inc. or Jidoka Technologies. It is not an ERP, MES, or WMS, and holds no accounting stock. It reads the line in real time, converts remaining material into minutes of production, and triggers replenishment before the line stops.

Your Challenges

The Hidden Cost of Manual Line Supply

Traditional kanban systems create bottlenecks that cost manufacturers time, money, and competitive advantage.

Paper-Based Kanban Cards

Physical kanban cards get lost, damaged, and create delays. Manual counting leads to inaccurate inventory data and replenishment errors.

Production Line Stoppages

Late material deliveries cause costly line stops. Without real-time consumption visibility, warehouse teams react too slowly to supply needs.

No Supply Chain Visibility

Disconnected systems create blind spots in material flow. Managers cannot see real-time stock levels at line stations or in warehouses.

Production Plan Changes

When production plans change, manual kanban systems cannot adapt quickly. Material requirements shift but supply orders remain unchanged.

Our Approach

How Jidoka Kanban Solves Line Supply

Four integrated capabilities that transform production line material supply from reactive to autonomous.

Autonomous Pull

Consumption-Driven Replenishment

Automatic detection of material consumption at the line triggers replenishment signals to the warehouse. No manual intervention, no cards, no delays.

Live Monitoring

Real-Time Supply Visibility

Live dashboards show material levels at every station, warehouse stock, and delivery status. Know exactly what is needed, where, and when.

Change Ready

Adaptive Supply Management

When production plans change, supply orders automatically adjust. Material requirements are recalculated and new pick lists are generated instantly.

Full Traceability

End-to-End Material Tracking

Every material movement is recorded — from warehouse shelf to production line consumption. Complete audit trail for quality and compliance.

Kanban Dashboard

Real-Time Production Line Status

See every line station's material status at a glance. Color-coded levels show what needs attention, active pull signals indicate in-progress replenishments, and countdown timers track delivery ETAs.

  • Station-level material monitoring with live level indicators
  • Automatic pull signals triggered by consumption thresholds
  • Real-time delivery tracking from warehouse to line station
  • Configurable alerts for low stock, delays, and anomalies
Smart Replenishment

Automated Just-in-Time Material Delivery

The line supply execution engine links production lines directly to material stores. When consumption is detected, pick lists are generated automatically, delivery routes are optimized, and warehouse operators receive prioritized task queues.

  • Automatic pick list generation based on real-time consumption
  • Optimized delivery routes between warehouse zones and line stations
  • Priority-based task queues for warehouse operators
  • Just-in-time delivery minimizing line-side inventory
Traceability & Analytics

Complete Material Visibility and Insights

Track every material lot from receiving to consumption on the production line. Generate detailed reports on consumption patterns, lead times, and supply efficiency. Manage moisture-sensitive components with automated exposure tracking.

  • Full lot traceability from warehouse receipt to line consumption
  • Consumption pattern analytics with efficiency metrics and trends
  • Moisture-sensitive component management with exposure time tracking
  • Automated reports for compliance, auditing, and continuous improvement
Case Study

Jidoka Kanban in Action

A success story in the automotive industry

A global automotive parts supplier managing complex production lines with multiple suppliers faced challenges with inventory management and production stoppages. After implementing Jidoka Kanban, they achieved remarkable results in operational efficiency and cost reduction.

Key Results Achieved:

57%
Reduced Inventory
91.2%
Reduced Line Stops
<3
Months ROI
Read Full Case Study
FAQ

Your Questions About Jidoka Kanban

Everything you need to know about autonomous production line supply

Jidoka Kanban is a hardware-software integrated system that autonomises production line material supply. Unlike traditional paper kanban cards or basic e-kanban systems, it provides real-time consumption detection, automatic replenishment signaling, and complete digital traceability — eliminating manual processes entirely.

The system combines software with sensor hardware installed at production line stations to detect material consumption in real time. The exact hardware configuration depends on your production setup and is determined during the implementation assessment. The software runs in the cloud and is accessible from any device.

Yes. Jidoka Kanban integrates with major ERP systems (SAP, Oracle, etc.), MES platforms, and warehouse management systems. The integration ensures synchronized data flow between production planning, warehouse operations, and line supply execution.

Typical implementation takes 2-4 months, including hardware installation, system configuration, integration with existing systems, and operator training. Most clients see measurable improvements within the first month of operation, with full ROI achieved in under 3 months.

Jidoka Kanban is designed for discrete manufacturing environments with production line supply needs. It is particularly effective in automotive, electronics, appliance manufacturing, and any industry with complex multi-component assembly lines requiring reliable just-in-time material supply.

The system automatically tracks exposure time for moisture-sensitive components (MSL levels). It monitors floor life from the moment a sealed package is opened, alerts operators when components approach exposure limits, and manages baking requirements to restore component viability.

In a documented deployment at an automotive parts supplier we measured a 57% reduction in line-side inventory, a 91.2% reduction in material-related line stoppages, and full ROI in under 3 months. That is one plant, not a guarantee — your results depend on line count, part mix, and supplier lead times. Alongside the numbers, the deployment eliminated paper-based processes, improved traceability for quality audits, and freed warehouse operator time.

A kanban module inside an ERP works with fixed quantities and thresholds, refreshed at intervals. Jidoka Kanban works with real consumption time, calculated from the line's actual speed at that moment. A fixed threshold does not know the line is running 12% above standard today; a calculation based on real tact time does. It does not replace the ERP module — it typically feeds it, sending the replenishment request in the format the ERP expects.

The system stores data locally for the duration of the outage and alerts the configured responsible parties. The connectivity availability requirement is 99.5%, with local failover. Materials already scanned on the line stay tracked; what is lost is forecasting precision while the connection is down.

Both. Access is role-based — administrator, manager, planner, operator, warehouse — with a full change log. AES-256 encryption at rest and TLS in transit.

Over 20 production lines and more than 50 concurrent users, with material availability recalculated in under 5 seconds and replenishment requests generated in under 10 seconds.

Part numbers with material type and packaging unit, the BOM structure with consumed quantities, product-to-line allocation, and hourly output per product per line. Changeover matrices and shift patterns are not required for the first phase. BOM accuracy determines the quality of the result more than anything else: if the BOM is wrong, the consumption calculation is wrong.
Ecosystem

Part of a Connected Manufacturing Ecosystem

Jidoka Kanban works seamlessly with other Share IT Smart solutions

Production Planning

MPS

Synchronize production schedules with material supply. MPS feeds demand signals directly into Jidoka Kanban for perfectly timed replenishment.

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Material Traceability

BatchTrace

Extend material traceability beyond the production line. BatchTrace captures lot-level data through every manufacturing step for complete quality records.

Learn More
Get Started

Ready to Autonomise Your Line Supply?

Discover how Jidoka Kanban eliminates manual kanban processes and prevents production line stoppages.

Supply Chain Diagnostic
Free assessment of your current line supply process and improvement opportunities.
Live System Demo
See Jidoka Kanban in action with a walkthrough of the dashboard, replenishment flow, and analytics.
Pilot Line Implementation
Start with one production line to prove results before scaling across your facility.
Start Your Assessmentoffice@share-it-smart.com · +40 736 909 455