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Pull / Kanban is a method of controlling the flow of production through the factory based on a customer’s demand. Pull Systems control the flow of resources in a production process by replacing only what has been consumed. They are customer order-driven production schedules based on actual demand and consumption rather than forecasting. Implementing Pull Systems can help you eliminate waste in handling, storing, and getting your product to the customer. Pull Systems are an excellent tool to use in the areas where cellular or flow manufacturing can not be achieved.
Workshop Objectives
The Pull/Kanban Systems workshop illustrates how to link manufacturing output to customer demand. Participants are lead through a six-step process for designing and implementing a pull system, using hands-on exercises. This process applies to both purchased and manufactured products. This group training exercise is designed to precede a Pull/Kanban implementation, or Kaizen event.
• Describe the difference between a Pull System and a Push System
• Identify opportunities to introduce Pull Systems
• Decide how to manage demand to meet customer requirements
• Locate and size supermarkets or buffers in the system
• Calculate order points and order quantities
• Select and implement appropriate Pull signals
• Recognize ways to monitor and fine-tune a Pull System
Topics Covered
| • Defining Lean | • Pull System Tools |
| • Push vs. Pull | • Selecting Appropriate Pull Signals |
| • Six Step Pull Systems Process | • Importance of training Personnel |
| • Determining Current State | • Implementation of Pull System |
| • Conceptualizing the Future State | • Pull System Case Studies |
| • Calculating Buffers | • Keys to Success |
| • Impact of Demand Variation | • Performance Impact and Benefits |
Kaizen Implementation Event
IMEC will facilitate a group of your employees through implementation of the Pull/Kanban process, in an area of your facility, utilizing the techniques learned in the workshop. Normally, everything cannot be implemented during the two or three day Kaizen event. Therefore, the team implement as many changes as possible within the allotted time, and will develop an action plan with assigned responsibilities and expected completion dates to insure that the necessary follow-up takes place.
Benefits of Pull Kanban
Successful implementation of a Pull / Kanban System will reduce lead times, minimize work in process, optimize floor space usage, simplify production signals and improve on-time delivery to your customers. |
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Continuous Process Improvement Links
Product/Process Flow Services |