Kanban and two-bin

On the wards, material is replenished by counting or by experience, and the time nurses spend in the storeroom is time they do not spend with patients. With two-bin and Kanban labels, each product has its place and its level, and replenishment arrives before anything runs out, without counts.

The challenge

On hospital wards, the storeroom and the ward supply kits are almost always managed by hand:

  • Stock levels are set by experience: some products are overstocked and others run short.
  • Nurses spend part of every shift counting, tidying and ordering material.
  • Shortages are solved with urgent orders to the central warehouse.
  • Kits are checked product by product and expiries surface late.

What we focus on

  • Levels calculated from actual consumption
  • Replenishment without counts
  • Organised ward storerooms and kits

Two-bin and Kanban labels

Each product takes up two bins. Material is used from the first; when it is empty, replenishment is requested and the second is used, so the new stock arrives before the product runs out.

Where two bins do not fit, or for bulkier products, Kanban labels are used: each product carries a label with its reorder level and, when that level is reached, the label triggers the order.

The replenishment signal can be recorded in the application or, where it adds most value, automatically with RFID. In the assessment we choose the format that fits each unit. More detail in RFID and traceability.

Ward supply kits too

The same method applies to ward kits: contents agreed with the unit, adjusted levels and expiries in view, without checking product by product.

It applies on hospital wards and in the central warehouse. For operating theatres and interventional suites, see Smart rooms and storerooms.

What changes

Less nursing time in the storeroom

No counts or manual orders on every shift.

Stock matched to consumption

Levels calculated from each unit’s actual consumption, with no excess or stock-outs.

Fewer urgent orders to the central warehouse

Replenishment arrives before material runs out.

Fewer expired products

With less idle stock and material used in order of arrival, less expires.

Capabilities

Level calculation and ward storeroom redesign

We analyse each unit’s consumption, clean up the catalogue and redesign the storeroom so the method works day to day.

Digital replenishment

Each replenishment signal is recorded in the platform and, through integration with the hospital’s ERP, can feed into the ordering process, with the scope defined in each project.

How we approach it

Kanban works when levels are well calculated and the storeroom is designed for the method. We start with a pilot unit and extend to the rest with what we learn.

1Unit assessment

Consumption, catalogue, available space and current ordering process.

2Design

Cleaned-up catalogue, levels per product, location and labelling of each bin.

3Go-live

Training for the unit team and digital replenishment; RFID where it adds value.

4Follow-up

Levels adjusted to actual consumption and roll-out to other units.

What we measure

  • Stock-outs on the wards
  • Nursing time spent in the storeroom
  • Value of stock on the wards
  • Urgent orders to the central warehouse
  • Expired material on the wards

Questions we are often asked

What is the two-bin system?

A replenishment method in which each product takes up two bins: when the first is empty, replenishment is requested and the second is used, with no need to count.

What is the difference between Kanban and two-bin?

Two-bin is a form of Kanban in which the empty bin itself signals that replenishment is needed; with Kanban labels, the signal comes from a label attached to each product. In both cases replenishment is driven by actual consumption, not by a periodic count.

Is RFID needed?

No. The method works with the signal recorded in the application; RFID is added where automating the signal adds most value.

Does it apply to ward supply kits?

Yes. The contents are agreed with each unit, and levels and expiries are controlled with the same method.

Does it connect to the hospital’s ERP?

Through integration, replenishment signals can feed into the ERP ordering process. The scope is defined in each project together with the IT team.

Where do we start?

With a pilot unit: assessment, design and go-live, then roll-out to the other units using what was learnt.

Shall we talk about how it applies to your hospital?

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