This document provides an overview of pull production in Lean manufacturing. It discusses the differences between push and pull systems, and how pull systems avoid waste by only producing what is needed. Kanban cards and one-piece flow are introduced as tools to implement a pull system. Kanban cards allow the customer to signal production needs and regulate workflow between processes. One-piece flow reduces waste by processing one item at a time through each process. Examples of pull systems in supermarkets and Kanban card usage in a supply chain are described. The benefits of pull systems like reduced inventory and self-regulating production schedules are also summarized.

1. T04
BASIC LEAN TRAINING
Principle 4
“Pull” production

2. Objectives
The objectives of this chapter are:
 To show pull and push effect in Lean.
 To show how to give the customer added
value by avoiding waiting and unnecessary
costs but at the same time avoid large
stocks and unnecessary waste.
 To show how one piece flow and Kanban
can be used instead of large badges.

3. Principle 4
Let the customer ask
“PULL” PRODUCTION
 Pull system
 Kanban
 One Piece Flow
Tools:

4. It’s the CUSTOMER that
pulls the flow
Internal / External
Let the CUSTOMER ask for product or service
PULL the production
Principle 4

5. "PUSH" SYSTEM;
Moving the materials
forward, without taking
into account whether or
not the task can be carried
out
"PULL" SYSTEM;
The materials are only
produced if needed and it
is delivered only when and
where it is needed.

6. Pull System pre-requisites
Areas where the customer can pick-up material
Customer / Supplier relation
Principle 4
Pull System
Process
A
Process
B
Process
C
12 min for the total order
3 min for the 1st piece

7. LIDL
VODAFONE
Question;
Are these services "PULL" or "PUSH"?

8. Some advantages:
 The customer is satisfied
immediately, there is no waiting
time
 Production scheduling is simplified
and self-regulating (Kanban)
 Service or production rhythm
defined by Takt Time
 Inventory is reduced
Principle 4
Pull System
Supermarkets

9. Principle 4
Kanban
What is Kanban?
• Kanban is a visual system for managing work as it moves through a process. Kanban
visualizes both the process (the workflow) and the actual work passing through that
process. The goal of Kanban is to identify potential bottlenecks in the process and fix
them, so work can flow through it cost-effectively at an optimal speed or throughput.

10. https://www.youtube.com/watch?v=Mdyyyu41dZ4

11. How does the supplier know that
he needs to produce?
Kanban
Principle 4
Kanban
Supermarkets

13. Supplier
Kanban cards
Customer
Max: 6 parts
Min: 2 parts
A
AA A
A A B
B B
B
B
B
C DA
B
C
CC
CC
C
DD
DD
D
D
Principle 4
Kanban
The customer asked for product C

14. Customer
A
AA A
A A B
B B
B
B
B
C DA
B C
CC
CC
C
DD
DD
D
D
Supplier
Kanban cards
Max: 6 parts
Min: 2 parts
Principle 4
Kanban
Operator fetches product C from warehouse

15. A
AA A
A A B
B B
B
B
B
C DA
B
CC
CC
C
C
DD
DD
D
D
Supplier
Kanban cards
Max: 6 parts
Min: 2 parts
Principle 4
Kanban
Customer
…and brings the correspondent coloured card

16. A
AA A
A A B
B B
B
B
B
C DA
B
CC
CC
C
C
DD
DD
D
D
Supplier
Kanban cards
Max: 6 parts
Min: 2 parts
Principle 4
Kanban
Customer
The card is placed in the Kanban board

17. Customer
A
AA A
A A B
B B
B
B
B
C DA
B
CC
CC
C
C
DD
DD
D
D
Supplier
Kanban cards
Max: 6 parts
Min: 2 parts
Principle 4
Kanban
And the product is delivered to the customer

18. Customer
A
AA A
A A B
B B
B
B
B
C DA
B
C
C
C
C
DD
DD
D
D
C
C
Supplier
Kanban cards
Control
Principle 4
Kanban
Purchasing
Max: 6 parts
Min: 2 parts
The sequence repeats until one card is placed on the yellow part
of the table.
An alert is sent to the purchasing department to buy new parts.

19. A
AA A
A A B
B B
B
B
B
C DA
B
C
C
C
DD
DD
D
D
CC
CC
Supplier
Kanban cards
Principle 4
Kanban
Max: 6 parts
Min: 2 parts When the minimum number of parts is achieved in
the warehouse, the supplier delivers new products...

20. A
AA A
A A B
B B
B
B
B
C DA
B
C
C
DD
DD
D
D
C
C
C
C
Supplier
Kanban cards
Max: 6 parts
Min: 2 parts
Principle 4
Kanban
…until the maximum number of parts is
achieved again.

21. A
AA A
A A
B
B B
B
B
B
C DA
B
DD
DD
D
D
C
C
CC
CC
Supplier
Kanban cards
Max: 6 parts
Min: 2 parts
Principle 4
Kanban
The cards return to the warehouse.
The system is Reset

22. Principle 4
Kanban
Types of Kanban signs
Empty spaces Computer signs Cards

23. Process | Hour 1 2 3 4 5 6 7 8 9
A   
B   
C   
Waiting time Lead time
Batch
Process
A
Process
B
Process
C
Process | Hour 1 2 3 4 5 6 7 8 9
A   
B   
C   
One Piece Flow
Process
A B C
Waiting time Lead time
Principle 4
One Piece Flow

24.  T04-G Envelope game

25. LEAN FOR WORK AND LEAN FOR LIFE
Train the trainer to teach Lean skills in VET