FACULTY OF ENGINEERING TECHNOLOGY

MANUFACTURING ENGINEERING TECHNOLOGY DEPARTMENT

LEAN MANUFACTURING (BETP 3804)
Pull System and Kanban
Tan Hauw Sen Rimo
Tan Hauw Sen Rimo PULL SYSTEM & KANBAN LEAN MANUFACTURING BETP 3804 2
Producing as many as possible (big Lot Size) in
expectation the customer will place order for the
products
Materials and parts are pushed into the production
operation before it starts.
Raw materials and parts are planned, scheduled and
acquired prior to the start of production.
It creates excessive and unnecessary inventory (raw
materials and work-in-process)

Push System
Tan Hauw Sen Rimo PULL SYSTEM & KANBAN LEAN MANUFACTURING BETP 3804 3
Requires top down production instruction
Produce in lot/batch
In process stock build up between processes
Lengthy production lead times
Push System Characteristic
Stamping Welding Assembly
WIP WIP Finished Product
Customer
Production Control
O
r
d
e
r
Production Schedule
Tan Hauw Sen Rimo PULL SYSTEM & KANBAN LEAN MANUFACTURING BETP 3804 4
Economic Production Quantity concept : the quantity of
the product to be made which have minimum cost by
considering inventory cost and set up cost
The lot size reflects the economic production quantity
Lots or Lot Size refers to how many items are being
produced in any given production run.
Lines are set up for the production of a given lot size.
In many production lines, only one item at a time can be
worked on at any given work station.
A lot size greater than what can be immediately worked on
creates inventory.
Lot sizes greater than what can be worked on results in
excess inventory sitting around idle.
Production Lot Size
Tan Hauw Sen Rimo PULL SYSTEM & KANBAN LEAN MANUFACTURING BETP 3804 5
Push System creates over production and high inventory
Over production and inventory is expensive
(Carrying/holding costs)
Reducing inventory saves money
Over production and inventory hides problems that create
inefficiency and increase costs.
Capacity problems, late vendor deliveries, imbalanced lines, equipment
problems
Reducing over production and inventory makes problems
visible so they can be corrected.

Problems in Push System
Tan Hauw Sen Rimo PULL SYSTEM & KANBAN LEAN MANUFACTURING BETP 3804 6
Eliminate wastes by creating Just in Time Production
Produce and deliver ONLY
What is needed
When is needed
In the quantity needed

How to Tackle the Problems
Tan Hauw Sen Rimo PULL SYSTEM & KANBAN LEAN MANUFACTURING BETP 3804 7
Takt Time
Continuous Flow
Pull System
JIT Components
Lean Principles :
1. Value
2. Value Stream
3. Flow
4. Pull
5. Perfection
Tan Hauw Sen Rimo PULL SYSTEM & KANBAN LEAN MANUFACTURING BETP 3804 8
Smaller lot sizes
Sequenced production
1 x 1 build one piece flow ideal lot size = 1
Continuous Flow
Tan Hauw Sen Rimo PULL SYSTEM & KANBAN LEAN MANUFACTURING BETP 3804 9
Continuous Flow
Stamping
Welding
Assembly Inspection
WIP
WIP
WIP
Finished Product Push System
Each operator builds
large lots at their own
pace
Lean Thinking
Reduce inventory
Reduce lead time
Reduce rework
Reduce defect
Better quality
Better communication
Tan Hauw Sen Rimo PULL SYSTEM & KANBAN LEAN MANUFACTURING BETP 3804 10
Lead Time Reduction
Process
Cycle Time (Minutes)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
Stamping
Welding
Assembly
Total Lead Time = 26 minutes for total production or 19 minutes for the 1
st
product
Process
Cycle Time (Minutes)
1 2 3 4 5 6 7 8 9 10
Stamping
Welding
Assembly
Push System
Lean Thinking
Total Lead Time = 10 minutes for total production
or 3 minutes for the 1
st
product
Tan Hauw Sen Rimo PULL SYSTEM & KANBAN LEAN MANUFACTURING BETP 3804 11
1. Connect processes
with same Takt Time
2. Processes laid out in
order of operation
3. 1x1 production within
area

Continuous Flow Design
Process 1 Process 2 Process 3 Process 4 Process 5
WIP WIP WIP WIP
Finished Product Raw Material
Process 1 Process 2
P
r
o
c
e
s
s

3
P r o c e s s 4P r o c e s s 5
Linier Production Line
U-Shape Workcell
Tan Hauw Sen Rimo PULL SYSTEM & KANBAN LEAN MANUFACTURING BETP 3804 12
Reduces lead time
Minimizes in process stock
Visually brings problems to the surface
Eliminates build up of defects

Benefits of Continuous Flow
Tan Hauw Sen Rimo PULL SYSTEM & KANBAN LEAN MANUFACTURING BETP 3804 13
Produce only exactly what needed, when need it and
in the needed quantity
Producing based on customers order in small lot size
Parts and materials are requested and delivered as
they are needed.
Materials & parts are pulled into the production
operation when needed.

Pull System
Tan Hauw Sen Rimo PULL SYSTEM & KANBAN LEAN MANUFACTURING BETP 3804 14
Downstream process
withdraws exactly what
needed, when need it, and
in the needed quantity
Upstream process
produces exactly what
needed, when need it, and
in the needed quantity
Pull System Characeristic
Upstream Process
Store
A
B
C
Downstream Process
Withdrawal Instruction
for component C
Production Instruction
for component C
Replenish
empty rack/bin/
container
Taiichi Ohno, early Toyota Engineer, got this idea
when visited American Supermarket, so this system
also known as Supermarket System
C
Tan Hauw Sen Rimo PULL SYSTEM & KANBAN LEAN MANUFACTURING BETP 3804 15
1. Store for Material/Parts on hand
[what is needed to produce finished parts/goods]
2. Store for finished parts/goods
[where are completed parts/goods kept]
3. Communication
[what, when, quantity]
Pull System Components
Tan Hauw Sen Rimo PULL SYSTEM & KANBAN LEAN MANUFACTURING BETP 3804 16
Material Store
Stamping Welding
Material/Parts Material/Parts
Material Store
All materials needed to build parts/products
[can replenish whatever taken/consumed/sold]
Located line side of consumer process
[visible pace of consumption/sales]


What is the
Quantity?
USEAGE lot sizes
Frequency of SUPPLY
Quantity per container
Tan Hauw Sen Rimo PULL SYSTEM & KANBAN LEAN MANUFACTURING BETP 3804 17
Finished Parts/Goods Store
Welding Assembly
Finished Parts/Goods Finished Parts/Goods
Finished Parts/Goods Store
Has all of finished parts/goods
[can replenish whatever taken/consumed/sold]
Located at the end of process
[visible pace of consumption/sales]


What is the
Quantity?
PRODUCTION lot sizes
Frequency of WITHDRAWAL
Quantity per container
Tan Hauw Sen Rimo PULL SYSTEM & KANBAN LEAN MANUFACTURING BETP 3804 18
Communication
Stamping
W
e
l
d
i
n
g
A s s e m b l y
Material/Parts Finished Parts/Goods
F
i
n
i
s
h
e
d

P
a
r
t
s
/
G
o
o
d
s
Finished Parts/Goods
Customer
Order
Supplier
Order
Tan Hauw Sen Rimo PULL SYSTEM & KANBAN LEAN MANUFACTURING BETP 3804 19
Purpose : Smooth and balanced pace of production
Authorize production and material conveyance
Visual check
Control over production
See ahead/behind condition
Process status at a glance

KANBAN - ()
Two Types of
KANBAN
Production Kanban Withdrawal Kanban
a Japanese word which roughly translated means card or ticket.
Key point :
It is a communication tool, a signal asking for material or asking for production
Tan Hauw Sen Rimo PULL SYSTEM & KANBAN LEAN MANUFACTURING BETP 3804 20
Contains all required information for team member to
complete process efficiently
Additional information to support visual management

KANBAN
Tan Hauw Sen Rimo PULL SYSTEM & KANBAN LEAN MANUFACTURING BETP 3804 21
Produces what is sold, when it is sold
Contains over production
Gives visual control of production system
Material [quantity, type, location]
Ahead/behind status at a glance
Creates self regulating production schedule
Bottom up schedule driven by customer demand
No need to constantly readjust manual schedules

Pull System Benefits
Tan Hauw Sen Rimo PULL SYSTEM & KANBAN LEAN MANUFACTURING BETP 3804 22
Known demand is necessary
Problem in one process will shut down the entire
production
Reducing lot size = Increasing cost (are you agree?)
Relies on consistent supply of material
Relies on equipment/machines availability and
reliability
Worker empowerment

Implementation Challenges