How can you implement a pull system in lean manufacturing to increase customer value?

1 What is a pull system?

A pull system is a type of production control system that regulates the amount and timing of work based on the signals from the downstream processes or the end customers. In other words, a pull system only produces what is needed, when it is needed, and where it is needed, in response to the demand. A pull system contrasts with a push system, which is based on the predetermined schedule or forecast of the upstream processes or the suppliers. A push system tends to create excess inventory, overproduction, and waste.

2 Why use a pull system?

A pull system has several advantages over a push system in terms of lean manufacturing and customer value. First, a pull system reduces inventory and work-in-progress, which frees up space, capital, and resources that can be used for other purposes. Second, a pull system improves quality and reduces defects, as it allows for faster feedback and correction of errors. Third, a pull system enhances flexibility and responsiveness, as it enables the production to adjust to the changing customer needs and preferences. Fourth, a pull system increases customer satisfaction and loyalty, as it delivers the right products at the right time and at the right place.

3 How to implement a pull system?

To implement a pull system in your manufacturing operations, you need to follow some steps. First, you need to identify your value stream, which is the sequence of activities that add value to your products from the raw materials to the final delivery. Second, you need to map your current state, which is the current flow of materials and information in your value stream. Third, you need to design your future state, which is the desired flow of materials and information in your value stream using the pull system principles. Fourth, you need to implement your future state, which is the actual execution of the changes and improvements in your value stream using the pull system tools.

4 What are the pull system tools?

Various tools can be used to implement a pull system in manufacturing operations. Kanban is a visual card or device that indicates the status and quantity of work in each stage of the value stream, helping to control inventory and synchronize production with customer demand. Supermarket is a buffer stock of finished goods or components that acts as a source of supply for downstream processes or customers, allowing for decoupling of production and reducing lead time and variability. FIFO lane is a first-in-first-out queue of work that ensures processing in the order of arrival, preventing accumulation of work and maintaining quality and consistency. CONWIP is a constant work-in-progress system that limits the total amount of work in the value stream, balancing production and reducing cycle time and waste.

5 How to measure and improve a pull system?

To measure and improve a pull system in your manufacturing operations, you need to monitor some key performance indicators (KPIs) and apply continuous improvement methods. Inventory turnover, lead time, throughput, and quality are all KPIs that can help you evaluate the effectiveness of your pull system. A higher inventory turnover indicates a lower inventory level and a higher customer demand, while a shorter lead time indicates a faster production and a higher customer satisfaction. Throughput is the rate of output produced by the value stream, while quality is the degree of conformity of the product to the customer specifications and expectations. PDCA, Kaizen, and Gemba are all continuous improvement methods that can help you optimize your pull system. PDCA involves identifying a problem, planning a solution, implementing the solution, checking the results, and acting on the feedback. Kaizen involves making small and incremental changes to the value stream to eliminate waste and increase value. Gemba involves going to the actual workplace where the value is created and observing the process and the people.