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Pull Manufacturing

Pull is a foundational element of Lean where the overriding goal is the elimination of waste. Pull allows for just in time inventory management which helps significantly reduce waste. Rather than pushing inventory to the floor whether its needed or not as some computer-based methods do, pull relies on inventory signals to replenish parts when and where they are needed in just the right amounts required to replenish customer demand. New material is produced only after old material has been consumed, thus eliminating waste.

Pull at Toyota is traditionally implemented using a Kanban (meaning card in Japanese) where each part travels with a card. When the part is consumed, the card is removed and signals that replenishment is needed. In environments like automotive, cards work well because there are a limited number of parts, volume is high, demand is stable, product mix is low and changeovers are infrequent.

But, what about environments where demand and processes are variable, equipment is shared and product mix changes frequently? A Kanban system of cards breaks down quickly under such conditions and without some type of pull, Lean becomes difficult if not impossible, to implement.

book_kanbanmixed.jpgImplementing a Mixed Model Kanban System

by James Vatalaro

 

book_kanbansimple.jpgKanban Made Simple

by John Gross

 

book_kanbanshopfloor.jpgKanban for the Shop Floor

by Productivity Press

 
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Lean Manufacturing - Just in Time, Factory Flow - 5S
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