How can you overcome challenges when implementing pull systems in manufacturing?

1 What are pull systems and why are they important?

A pull system is a production method that relies on signals from the downstream process or the customer to trigger the upstream process or the supplier to produce or deliver the required items. This way, the production is driven by the actual demand, rather than by forecasts or schedules. Pull systems can help you reduce inventory levels, avoid overproduction, eliminate bottlenecks, improve quality, and increase customer satisfaction.

2 How to manage inventory in a pull system?

One of the main challenges of implementing a pull system is to manage the inventory levels of raw materials, work-in-progress, and finished goods. You need to ensure that you have enough inventory to meet the customer demand, but not too much that you incur unnecessary costs and risks. To achieve this, you need to calculate the optimal inventory levels based on the lead time, the demand variability, and the service level. You also need to monitor the inventory levels regularly and adjust them according to the changes in demand or supply.

3 How to balance production in a pull system?

Another challenge of implementing a pull system is to balance the production capacity and the demand across the different stages of the manufacturing process. You need to avoid overloading or underutilizing any of the resources, such as machines, workers, or space. To achieve this, you need to design the production layout and the workflow to minimize the distance and the time between the processes. You also need to use tools such as kanban cards, andon lights, or heijunka boxes to control the production pace and synchronize the activities.

4 How to align suppliers in a pull system?

A third challenge of implementing a pull system is to align the suppliers with the pull philosophy and the customer demand. You need to ensure that the suppliers can deliver the right quantity and quality of materials at the right time and place. To achieve this, you need to establish long-term and collaborative relationships with the suppliers, based on trust, communication, and feedback. You also need to share the demand information and the inventory levels with the suppliers, and use techniques such as vendor-managed inventory, consignment inventory, or just-in-time delivery to optimize the supply chain.

Implementing pull systems in manufacturing can be challenging, but it can also be rewarding. By following these tips, you can overcome the common obstacles and enjoy the advantages of pull systems in your manufacturing process.

5 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?