Pull Systems
A pull system regulates the flow of resources in a manufacturing process by replacing only what has been consumed and only what is immediately deliverable. As a result, your business becomes increasingly lean, eliminating excess inventories of raw materials, work in process, and finished goods. Customer orders drive production schedules based on actual demand and consumption rather than forecasting.
One of the most important tools in a pull system is kanban. Based on a proven Japanese model, kanban is a visual approach to production control, using simple tools like returnable containers, cards, or even empty spaces to “pull” products from “producing” workstations or suppliers toward “consuming” workstations or businesses. In this context, “a kanban” is a sign or visual aid indicating that a work center has finished a process, requires work, or needs more materials. Kanbans enable work centers to track supplier or customer needs and respond quickly and appropriately.
Our consultants first work with your teams to determine where pull systems can best be applied. We then help them determine the details of a kanban approach, including the use of supermarket sizes (where larger stacks of components are stored), order points, order quantities, and communication with suppliers.
Benefits
Pull systems are an economical way to:
- Simplify communications
- Reduce inventory
- Shorten and control lead times
- Reduce work in process
- Reduce order turnaround time
- Increase customer satisfaction
- Improve cash flow
- Reduce cycle time