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How can you design a pull system in a Kanban system for minimal waste and variability?

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A pull system is a way of managing the flow of work in a manufacturing process, where each stage only produces what is requested by the next stage. This reduces overproduction, inventory, and waste, and improves quality and customer satisfaction. A Kanban system is a visual tool that helps implement a pull system, using cards, boards, bins, or other signals to indicate the status and demand of work items. In this article, you will learn how to design a pull system in a Kanban system for minimal waste and variability.

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Adedeji B.

Engineering || Supply Chain and Logistics || Operations Management || R & D || Renewable Energy.

1 Understand the value stream

The first step in designing a pull system is to map out the value stream of your product or service, from the customer's perspective. This means identifying all the steps, activities, inputs, outputs, and resources involved in creating and delivering value to the customer. You can use tools like value stream mapping or process flow diagrams to visualize the current state of your value stream and identify the sources of waste and inefficiency.

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Adedeji B.

Engineering || Supply Chain and Logistics || Operations Management || R & D || Renewable Energy.
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A pull system in a Kanban system is a way of managing work by only starting new tasks when there is a demand for them. This helps to reduce waste and variability by avoiding overproduction and optimizing the flow of work.

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2 Define the pull units

The next step is to define the pull units, which are the smallest batches of work that can be moved along the value stream. The pull units should be based on the customer's demand and the capacity of each process stage. The smaller the pull units, the more flexible and responsive the system will be, but also the more frequent the signals and transactions will be. You can use tools like takt time, cycle time, and throughput to calculate the optimal pull unit size for each stage.

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Adedeji B.

Engineering || Supply Chain and Logistics || Operations Management || R & D || Renewable Energy.
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To design a pull system in a Kanban system: - Visualize your workflow on a Kanban board with columns for each stage of the process and cards for each task. - Set work-in-progress limits for each column to control how many tasks can be in each stage at a time. This prevents bottlenecks and ensures a smooth flow of work. - Use visual signals, such as colors, icons to indicate the status and priority of each task. This helps to communicate the information and expectations to the team and the stakeholders. - Monitor and measure the performance of the system using metrics such as lead time, cycle time, throughput, and quality. This helps to identify and eliminate waste and variability and improve the efficiency and effectiveness of the system.

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3 Design the Kanban system

The third step is to design the Kanban system, which is the mechanism that controls the flow of pull units in the value stream. A Kanban system consists of three elements: Kanban cards, Kanban boards, and Kanban bins. Kanban cards are the signals that represent the pull units and their status. Kanban boards are the visual displays that show the workflow and the location of the Kanban cards. Kanban bins are the containers that hold the pull units and the Kanban cards. You can use tools like Kanban board templates, Kanban card formats, and Kanban bin sizes to design your Kanban system.

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4 Set the WIP limits

The fourth step is to set the work-in-progress (WIP) limits, which are the maximum number of pull units that can be in each stage of the value stream at any given time. WIP limits prevent overproduction, congestion, and waste, and encourage smooth and balanced flow. WIP limits should be based on the demand, capacity, and variability of each stage. You can use tools like Little's law, queueing theory, and buffer analysis to determine the appropriate WIP limits for each stage.

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5 Implement the pull system

The fifth step is to implement the pull system, which is the process of operating the Kanban system according to the pull logic. The pull logic is simple: a stage can only start working on a new pull unit when it receives a Kanban card from the next stage, and it must send a Kanban card to the previous stage when it finishes a pull unit. This way, the work flow is driven by the customer's demand and synchronized with the value stream. You can use tools like standard work, visual management, and team communication to implement the pull system.

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6 Monitor and improve the system

The sixth and final step is to monitor and improve the system, which is the process of measuring the performance and effectiveness of the pull system and making adjustments as needed. The pull system is not a static or rigid system, but a dynamic and adaptive system that responds to changes in the environment and the customer's needs. You can use tools like key performance indicators, feedback loops, and continuous improvement methods to monitor and improve the system.

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7 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 can you design a pull system in a Kanban system for minimal waste and variability?

1

2

3

4

5

6

7

1 Understand the value stream

2 Define the pull units

3 Design the Kanban system

4 Set the WIP limits

5 Implement the pull system

6 Monitor and improve the system

7 Here’s what else to consider

Manufacturing Engineering

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How can you design a pull system in a Kanban system for minimal waste and variability?

1

2

3

4

5

6

7

1 Understand the value stream

2 Define the pull units

3 Design the Kanban system

4 Set the WIP limits

5 Implement the pull system

6 Monitor and improve the system

7 Here’s what else to consider

Manufacturing Engineering

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