The Lean EnterpriseThe Lean EnterpriseThe Lean EnterpriseThe Lean EnterprisePush versus Pull
Lean Foundations
Continuous Improvement Training
Lean Foundations
Continuous Improvement Training
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The purpose of the module is to allow you to become familiar with the distinction
between Push and Pull systems.
PurposePurposePurposePurpose
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Pull and Flow . . . .Pull and Flow . . . .
Principles of Process Analysis
FlowFlow Pull Systems
FlowFlow Pull Systems
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Actions Required to get improved Actions Required to get improved f - l - o - wf - l - o - wActions Required to get improved Actions Required to get improved f - l - o - wf - l - o - w
Batch Size Reduce Set-Up times and cut lot sizes Reduce Set-Up times and cut lot sizes “ “Fewer piece flow” - 1 piece is usually betterFewer piece flow” - 1 piece is usually better
People
Multiple Skill DevelopmentMultiple Skill Development Multiple Process HandlingMultiple Process Handling
Materials
Eliminate “Isolated Islands”Eliminate “Isolated Islands”
Machines
Laid out in processing orderLaid out in processing order “ “right” machines to ensure the flowright” machines to ensure the flow
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Pull and Flow . . . .Pull and Flow . . . .
Principles of Lean Thinking
Flow
Pull SystemsPull Systems
Flow
Pull SystemsPull Systems
PUSH vs. PULL SYSTEMSPUSH vs. PULL SYSTEMS
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Push vs Pull:Push vs Pull: What IS the Difference ? What IS the Difference ?Push vs Pull:Push vs Pull: What IS the Difference ? What IS the Difference ?
A requirement of any production operation is to A requirement of any production operation is to enable everyone to know exactly:enable everyone to know exactly:
- what product is needed- what product is needed - by when- by when - in what quantity- in what quantity
There are two ways to do it:There are two ways to do it:
Here’s One WayHere’s One Way - issue PRODUCTION SCHEDULES - issue PRODUCTION SCHEDULES to every process using the parts from one process to every process using the parts from one process to drive the work at the next process - in essence to drive the work at the next process - in essence PUSHING THE PARTS THROUGH THE SYSTEMPUSHING THE PARTS THROUGH THE SYSTEM
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Push vs Pull:Push vs Pull: What IS the Difference ? What IS the Difference ?Push vs Pull:Push vs Pull: What IS the Difference ? What IS the Difference ?
A requirement of any production operation is to A requirement of any production operation is to enable everyone to know exactly:enable everyone to know exactly:
- what product is needed- what product is needed - by when- by when - in what quantity - in what quantity
There are two ways to do it:There are two ways to do it:
ONE WAYONE WAY - issue PRODUCTION SCHEDULES to - issue PRODUCTION SCHEDULES to every process using the parts from one process to every process using the parts from one process to drive the work at the next process - in essence drive the work at the next process - in essence PUSHING THE PARTS THROUGH THE SYSTEMPUSHING THE PARTS THROUGH THE SYSTEM
ANOTHER WAYANOTHER WAY - letting a process withdraw the - letting a process withdraw the parts from a preceding process or PULLING THE parts from a preceding process or PULLING THE PARTS THROUGHPARTS THROUGH
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Push SystemsPush Systems Push SystemsPush Systems
Driven by Forecasts Parts are sent to the next Operation or stored in WIP The second operation continues even if there is a large amount of WIP from the first operation Buffers cover problems Expeditors push Hot parts
PUSH SYSTEMS HAVE NO PUSH SYSTEMS HAVE NO DISCIPLINE ON INVENTORYDISCIPLINE ON INVENTORY
More is always betterMore is always better
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Pull ProductionPull ProductionPull ProductionPull Production
The Customer usageCustomer usage rate rate determines the
production rate in a PULL SYSTEM.
“TAKT TIME” is …
that customer usage rate.
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Pull ProductionPull ProductionPull ProductionPull Production
Establishment of Pull systems
between operations in the same plant Connection of operations that are at a
distance from each other Elimination of inter-departmental
scheduling
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Pull ProductionPull ProductionPull ProductionPull Production
Produces only what’s required by the
next operation The user withdraws from the producer Kanbans or Visual Systems signal the
need for more Everyone sees what’s required
The Lean EnterpriseThe Lean EnterpriseThe Lean EnterpriseThe Lean EnterprisePush versus Pull
Lean Foundations
Continuous Improvement Training
Lean Foundations
Continuous Improvement Training
