Introduction to Pull system - November 2016

1Marek.Piatkowski@Rogers.com
Pull System
Introduction
Thinkingwin, Win, WIN
Pull System
Introduction
Marek Piatkowski – November 2016

Pull System
Introduction
Introduction - Marek Piatkowski
 Professional Background
 Toyota Motor Manufacturing Canada (TMMC) - Cambridge, Ontario from
1987-1994
 TPS/Lean Transformation Consulting - since 1994
 Professional Affiliations
 TWI Network – John Shook, Founder
 Lean Enterprise Institute (LEI) – Jim Womack
 Lean Enterprise Academy (LEA) – Daniel Jones
 CCM/CAINTRA – Monterrey, Mexico
 SME, AME, ASQ, CME
 Lean Manufacturing Solutions - Toronto, Canada
http://twi-network.com

Pull System
Introduction

Pull System
Introduction
What is a Pull System?

Pull System
Introduction
TPS
(ToyotaProductionSystem)
is born
Roots of Lean
1950 - 51
1951

Pull System
Introduction
Mr. Ohno's Idea
Food Mart
Supermarket
Warehouse

Pull System
Introduction
Supermarket for Manufacturing

Pull System
Introduction
Food Mart
Supermarket
Sign
Stockroom
The Supermarket Model

Pull System
Introduction
The Supermarket Suppliers
Food Mart
Supermarket
Warehouse
Supplier Supplier
Stockroom

Pull System
Introduction
“Shopping” at a Supermarket
 No Purchased Order required
 No schedule of what I need and when
 Supermarkets are open 24/7
 EVERYRYTHING is available – there are no shortages
 All Supermarkets (anywhere in the World) have a standard layout

Pull System
Introduction
Can Supermarket principles work in Manufacturing?

Pull System
Introduction
Scheduling Production – Traditional vs Pull
 In conventional production systems, parts produced at one process, as determined
by the production schedule, are delivered to succeeding processes even if they are
not yet needed there.
 This method may be good when parts can be produced on schedule throughout
the whole process.
 But if just one process has trouble and the line stops, the processes directly related
to the troubled one will suffer from either a shortage or a backup of parts
 The pull system is designed to allow production of parts based on usage
(consumption) - unless an employee from the following process goes to the
preceding process to pick up the parts, the preceding process must not produce
any more parts than required.

Pull System
Introduction
Production Schedule Changes
 In the traditional production control system, a method of adapting to a change in
customer demands is met by issuing various production schedules to all of the
processes.
 These processes produce parts in accordance with their schedules, employing the
method of the previous process supplying the parts to the next process, or, the
push system.
 However, this method will make it difficult to promptly adapt to changes caused by
machine downtime, part shortages or by demand fluctuations.
 As a result, the company must hold inventory among all processes in order to
absorb problems and demand fluctuations.
 Thus, such a system often creates an imbalance of stock between processes and
parts shortages, which often leads to additional (just-in-case) inventory.

Pull System
Introduction
The Push System
Slide: 5
Material
Control
Customer
Order Push
Push
Push
Parts
Order Push
Components
Order
Push
Supplier
Parts Delivery
Temporary Storage
Push
Sub-AssemblyPush Push
Final Assembly
Push
Customer Push
Finished Goods Delivery
Push
Lead Time = Max

Pull System
Introduction
Pull System
 In a traditional operation Production Scheduling department generates
Information by issuing schedules to all departments to produce and to move
material.
 Toyota reversed that process. At Toyota only material movement generates
Information Flow - A Pull Signal (Kanban).
 When parts are “pulled” from the Supermarket, a signal (Kanban) is sent to the
supplying process to produce more.
 Schedule is issued only to the Pacemaker process.
 This is called a Pull System.

Pull System
Introduction
Pull System
 In the Toyota Production System the next process withdraws parts from the
previous process. This method is known as a Pull System.
 Since only the final assembly line can accurately know the necessary timing and the
amount of parts required, the final assembly will pull the needed parts:
 in the needed amount
 at the needed time
 from the warehouse or the previous process.
 The previous process then produces the parts withdrawn by the next process.
 Further, each part-producing process withdraws the necessary parts or materials
from the previous process or the supplier further down the line.

Pull System
Introduction
The Pull System
Slide: 6
Customer
Order Pull
Parts
Order
Supplier
Parts Delivery
Sub-Assembly
Final AssemblyCustomer
Finished Goods Delivery
PullPull
Pull
Pull
Pull
Pull
Lead Time = Min
Finished Goods
Pull
Temporary Storage

Pull System
Introduction
Advantages of a Pull System
 We do not have to depend on a Customer forecast, which in a lot of cases is
inaccurate, to schedule production and to order parts and components
 We produce only what is needed or we deliver what is needed – based on a pull
system the Supermarket
 We control our inventory through the use of Kanbans
 We can easily tell what parts we have and what parts we need – we do not waist
time looking for parts
 The Pull System should:
 Eliminate part shortages
 Tell us to build only what the Customer needs

Pull System
Introduction
What is a
Pull System?

Pull System
Introduction
Kanban
 However, when each process is physically separate from the others, transportation
is required. An operator of the following process goes to the preceding process to
pull parts as needed (Pull system).
 The method used to exchange information between the pull and fill-up production
sites is a Kanban.

Pull System
Introduction
Changing the World. One Transformation at a time
This presentation is an intellectual property of W3 Group Canada Inc.
No parts of this document can be copied or reproduced
without written permission from:
Marek Piatkowski
W3 Group Canada Inc.
iPhone: 416-235-2631
Cell: 248-207-0416
Marek.Piatkowski@rogers.com
http://twi-network.com

Pull System
Introduction
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Introduction to Pull system - November 2016

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