Pull Systems / Kanban

Reduce Lead Time, Accelerate Inventory Turns, Improve Production Flow and Simplify Scheduling.

House of Lean

Benefits of Pull Systems

• Reduces inventory requirements and floor space
• Increases productivity
• Links producing and consuming processes
• Establishes appropriate inventory and lot sizes
• Improves on-time delivery
• Improves lead-time

Pull Systems are scheduling and information systems designed to improve the flow of materials and work in process (WIP). They control the allocation of resources based upon actual consumption rather than on forecasted demand. Pull Systems link consuming and producing processes to enable a reduction in WIP and floor space. The impact of the effective implementation of this methodology will include significant increases in throughput, inventory turns, cash flow, ROI and profitability.

The Process

As with most concepts of lean manufacturing, the first step is to select a product family and document current and desired future states through value stream mapping. Upon completion of the mapping process, the following steps are typically taken to introduce Pull Systems into the value stream:

• Determine which end items will be build-to-order and which will be build-to-stock. Considerations include:
  • Customers' desired lead-time relative to the manufacturing time
  • Rate and variability of customer demand
  • Confidence in design and configuration
  • Equipment changeover duration at key production points
• Identify combinations of process steps where continuous flow is possible.
• Establish FIFO lanes where flow is possible and kanban supermarkets where flow is not possible. Calculate maximum quantities for FIFO lanes and supermarkets.
• Determine what single point in the value stream will be used to trigger production.
• Establish standard re-order quantities for all assemblies and component parts.

As the process evolves the changes and results are measured and monitored to evaluate effectiveness. Once the system has stabilized and the company has a grasp of how to manage pull systems, the methods can be expanded into other areas of the facility. It should be noted that, like many tools of lean manufacturing, Pull Systems lend themselves to continuous improvement. Also, periodic adjustments are necessary to accommodate changes in customer demand, vendor responsiveness, manufacturing processes, etc.

Our Experience and Track Record

Insyte Consulting has Western New York's largest and most diverse staff of Lean Six Sigma (LSS) manufacturing experts — all with extensive hands-on, industry experience. We have helped WNY companies improve operations using lean manufacturing methodologies for over 25 years. Insyte has worked successfully with more WNY companies using these techniques than any other consulting organization. We welcome the opportunity to discuss your specific situation and how we may contribute to your improved competitiveness and profitability using proven lean manufacturing tools.

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