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How do you integrate lean principles and tools with other quality management approaches in your pull system?

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Lean management is a philosophy and a set of practices that aim to eliminate waste, improve quality, and increase customer satisfaction. One of the key elements of lean management is the pull system, which is a way of controlling the flow of materials and information based on the actual demand from the customer or the downstream process. In a pull system, you only produce or deliver what is needed, when it is needed, and in the right quantity and quality. This reduces overproduction, inventory, and waiting time, and enhances flexibility and responsiveness.

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1 Benefits of pull system

Implementing a pull system can bring several advantages to your organization. It can reduce costs and waste, improve quality and customer satisfaction, increase efficiency and productivity, and enhance flexibility and agility. Additionally, a pull system can foster continuous improvement and innovation by identifying and eliminating root causes of problems, implementing solutions, and learning from feedback.

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2 Lean principles and tools for pull system

To successfully implement and maintain a pull system, you need to apply some of the core lean principles and tools. Value stream mapping (VSM), for example, is a technique to visualize and analyze the current and future state of your process, from the source of inputs to the delivery of outputs. This helps identify value-added and non-value-added activities, sources of waste, and opportunities for improvement. Additionally, Kanban is a method to regulate the flow of work by using visual signals, such as cards, boards, or bins. This helps balance the supply and demand, limit work in progress (WIP), and prevent overloading or starving the system. Heijunka is another concept which levels production or service delivery by smoothing variation in demand, volume, and mix. Finally, Kaizen is a culture of continuous improvement that involves everyone in finding and solving problems, making small changes, and measuring and sustaining the results.

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3 Integration with other quality management approaches

Lean management is not the only quality management approach you can use to improve your pull system. Other methodologies and frameworks, such as Six Sigma, Total Quality Management (TQM), and ISO 9001, can complement and enhance your lean efforts. Six Sigma uses a five-phase process called DMAIC to identify and solve problems, implement solutions, and monitor performance. It can help you measure and improve the quality of your pull system by using tools such as statistical process control (SPC), failure mode and effects analysis (FMEA), and root cause analysis (RCA). TQM focuses on customer satisfaction, employee involvement, process improvement, and strategic alignment. It can help you align your pull system with your vision, mission, values, and goals, and engage employees in improving quality by using tools such as quality circles, benchmarking, and quality audits. ISO 9001 is an international standard that specifies the requirements for a quality management system (QMS) to demonstrate its ability to consistently provide products or services that meet customer and regulatory requirements. It can help you establish, document, implement, maintain, and improve your pull system by using tools such as quality policy, objectives, manual, procedures, records, and audits.

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Kirk J. Gould - MBA, Engineer

Business Acceleration
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Six Sigma can work well with automated mechancial production processes. In order to take full advantage though, the Lean foundation of respect for people and continuous improvement must be in place. Let's look at an example. Filling out an expense report likely has a mistake one out of three times in real life. If we thought that we might achieve a six sigma quality level with Expense Reports we may be sorely disappointed. 3.8 per million is quite a long way from 1 out of 3. So we need to be realistic. We also need to understand that people are the company, not machines or financial reports. People own companies, get paychecks from companies, and apply effort to companies.

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4 Tips for successful integration

Integrating lean principles and tools with other quality management approaches in your pull system can be challenging, but rewarding. To ensure success, you should begin by understanding customer needs and expectations, as well as your value proposition and competitive advantage. Involve stakeholders in the design, implementation, and improvement of your pull system to gain their buy-in and feedback. Choose compatible quality management approaches that are appropriate for your industry and context. Implement the system and approaches using the PDCA cycle and monitor results to identify gaps and make adjustments. Finally, continue learning by seeking best practices, benchmarking performance, and applying lessons learned.

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Jodi McMahon, MSEM

Leader dedicated to continuous improvement for all aspects of business - everything gets better with Lean Sigma
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One thing that helps with integration is making sure all leadership is on board with the integration. Integration should be a strategic project with top leadership sponsorship, until all aspects of the integration is complete. It's further recommended that the system be called a business management system (BSM). The BSM incorporates the individual philosophies, standards, and approaches. For example, Lean Sigma is the continual improvement approach. ISO 9001 provides the requirements for setting up document control and leadership oversight.

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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?

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How do you integrate lean principles and tools with other quality management approaches in your pull system?

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1 Benefits of pull system

2 Lean principles and tools for pull system

3 Integration with other quality management approaches

4 Tips for successful integration

5 Here’s what else to consider

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