jueves, 23 de octubre de 2014

Pull Production Systems 生産システムを引いて- The benefits and a brief description.

Push Production Systems: a forecast of future demand drives production
scheduling and material replenishment.  Planned orders are used to authorize
production or move materials – usually in batch mode

Push Production Systems are…
    • Inherently complex and inflexible
    • Usually computer based (no visible system)
    • Labor intensive, requiring significant labor-hours to keep the system accurate and up-to-date
    • Incapable of reacting quickly or accurately to the frequent, small demand changes common to production operations

A Pull Production System has three major tasks:
    • Get materials to the shop floor based on actual consumption
    • Move work-in-process (WIP) through the shop based on actual customer demand
    • Provide a mechanism for continuously improving the production processes

If the meaning of production control is truly understood, inventory control is unnecessary.
                                              -- Taiichi Ohno

Safety Stock is WASTE
Safety stock is excess inventory in a system to account for variations
    • Demand
    • Lead time
    • Supplier performance
    • Poor quality
    • Differences between calendar days and work days
    • E.g., Production works on Saturday, but suppliers don’t deliver on Saturday


Kanban is a Japanese word, which loosely translated means sign or card
We use Kanban signals to pull product through the process, AND to
replenish raw material
Use Kanban when processes are separated
    • Lines with multiple back ends
    • Outside suppliers
    • Feeder cells
    • Semi-finished goods
    • Finished goods with our customers!

2-Bin Replenishment System

Goals of a 2-bin system:
    • Ensure operator always has parts
    • Ensure operator does not have to leave bench to find parts
    • Ensure material availability status is VISIBLE
    • Minimize the amount of raw material kept on the production floor

Kanban and Materials Management

Small parts: use the container/bin as Kanban signal
    • It is the container that goes back and forth for replenishment
Large / expensive parts: use Kanban card Where possible raw
material should be removed from stores (warehouse) and put on the
production floor in point-of-use (POU) locations.  Strive to eliminate
    • Appropriate quantities in POU depends on:
    • physical size
    • material cost
    • frequency of usage
    • frequency of replenishment

Material Handling Function

In a continuous flow cell, if operators abandon their stations to retrieve parts, the adjacent operations will quickly shut down.  A separate material handling role will need to be responsible for part retrieval, removal of empty part containers, and handling of part scrap/fallout

Consumption is the signal for activity
Signal is located in the producing
Producing area is buffered from
extreme variation in demand

Simplifies planning and control system
Converts shop floor into an assembly line
Controls production through adherence to
pull rules

    • standard containers
    • standard quantities
    • authorized production

4 comentarios:

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  2. Alex, excellent content and examples! Keep sharing and adding value to our knowledge.

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