Introduction to Pull system - November 2016
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Transcript of Introduction to Pull system - November 2016
Pull System Introduction
Thinking win, Win, WIN
Pull SystemIntroduction
Marek Piatkowski – November 2016
Thinking win, Win, WIN
Pull System Introduction
Thinking win, Win, WIN
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
Thinking win, Win, WIN
TPS(Toyota Production System)
is born
Roots of Lean
1950 - 51
1951
Pull System Introduction
Thinking win, Win, WIN
M r. Ohno's Idea
Food M art
Supermarket
W areho use
Pull System Introduction
Thinking win, Win, WIN
Food M art
Supermarket
S ignS tock ro om
The Superm arket M odel
Pull System Introduction
Thinking win, Win, WIN
The Superm arket Suppliers
Food M art
Supermarket
W arehouse
S u p p lie r S u p p lie r
S tock room
Pull System Introduction
Thinking win, Win, WIN
“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
Thinking win, Win, WIN
Can Supermarket principles work in Manufacturing?
Pull System Introduction
Thinking win, Win, WIN
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
Thinking win, Win, WIN
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
Thinking win, Win, WIN
The Push System
Slide: 5
MaterialControl
CustomerOrder Push
Push
PushPartsOrder Push
ComponentsOrder
Push
SupplierParts Delivery
Temporary Storage
Push
Sub-AssemblyPush Push
Final Assembly
Push
Customer Push
Finished Goods Delivery
Push
Lead Time = Max
Pull System Introduction
Thinking win, Win, WIN
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
Thinking win, Win, WIN
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
Thinking win, Win, WIN
The Pull System
Slide: 6
CustomerOrder Pull
PartsOrder
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
Thinking win, Win, WIN
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
Thinking win, Win, WIN
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
Thinking win, Win, WIN
Changing the World. One Transformation at a timeThis presentation is an intellectual property of W3 Group Canada Inc.
No parts of this document can be copied or reproducedwithout written permission from:
Marek PiatkowskiW3 Group Canada Inc.iPhone: 416-235-2631
Cell: 248-207-0416
[email protected]://twi-network.com
Pull System Introduction
Thinking win, Win, WIN
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