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Technical Lean Tools 06: Pull System(s)

Module: 05 Technical Lean Tools Section: 06 Pull System(s) Course Description: This section introduces one of the hallmarks of lean manufacturing programs, the Pull System. There is an initial review of traditional approaches (it is HIGHLY recommended to review the MiFLOW section from the Measurement Module before starting this section) and then a discussion of the fundamentals of a variety of pull system designs. There is also special attention paid to the methods of reducing lot sizes – a necessary requirement to successfully incorporate a Pull System. The concept and application of kanban is also introduced and discussed. Material covered in this section: Traditional System Pull System Store Material stock Communication Kanban Types of Pull Systems Type A Type B Type C Optimum lot sizes Quick changeover Small lot summary While Pull Systems offer many advantages - lead time reduction, self-managed production, visual management, standardized communication, and inventory reduction (to name a few) – these systems are generally a large departure from the traditional methods they replace. As such, it can be a challenging cultural transition. As with Continuous Flow, it is crucial to have a firm lean foundation in place before layering the Pull System on top. Good Lean Problem Solving, Lean Management, and a firm grasp of the requisite tools will provide the smoothest transition and minimize the frustrations associated with major organizational changes. See more at www.conceptsoflean.com