What are the key differences and similarities between pull and kanban?

1 Pull system

A pull system is a way of organizing production or service delivery based on customer demand. Instead of pushing work or materials through the process, a pull system triggers the next activity only when there is a need or a request from downstream. This prevents overproduction, excess inventory, and unnecessary costs. A pull system also enables faster response, higher quality, and more flexibility. However, a pull system requires accurate forecasting, reliable suppliers, and clear communication among the different stages of the process.

2 Kanban system

A kanban system is a type of pull system that uses visual signals to indicate the status and availability of work or materials. The word kanban means "card" or "sign" in Japanese, and it refers to the labels or cards that are attached to containers or bins of items. A kanban system regulates the flow of work or materials by limiting the number and size of containers or bins, and by setting rules for when to replenish them. A kanban system helps to reduce waste, improve efficiency, and increase visibility. However, a kanban system requires constant monitoring, adjustment, and collaboration among the different parties involved.

3 Similarities between pull and kanban

Both pull and kanban systems share some common principles and goals. They both aim to eliminate waste, especially waste related to overproduction and inventory. They both focus on delivering value to customers by meeting their needs and expectations. They both rely on feedback and data to improve the process and solve problems. They both empower the workers to make decisions and take ownership of their work. They both foster a culture of continuous improvement and learning.

4 Differences between pull and kanban

Despite their similarities, pull and kanban systems also have some notable differences. One difference is the level of detail and specificity involved. A pull system can be applied at a high level, such as a product line or a service category, while a kanban system is more granular, such as a specific task or a single item. Another difference is the type and frequency of triggers. A pull system can be triggered by various signals, such as orders, requests, or forecasts, while a kanban system is triggered by predefined rules, such as minimum or maximum levels of inventory. A third difference is the degree of standardization and customization. A pull system can be more flexible and adaptable to changing customer demands, while a kanban system can be more consistent and predictable in terms of quality and delivery.

5 How to choose between pull and kanban

There is no definitive answer to which system is better or more suitable for your situation, as it depends on several factors such as product type, customer segment, market conditions, operational capabilities, and organizational culture. However, some general guidelines can help you decide. For instance, if you have a high variety or customization of products or services, a pull system may be more appropriate as it allows you to respond to customer preferences and specifications. Alternatively, if you have a low variety or standardization of products or services, a kanban system may be more suitable for optimizing your production or service delivery process and reducing waste. Additionally, if you have a high demand variability or uncertainty, a pull system can reduce the risk of overproduction or underproduction and improve your agility and resilience. On the other hand, if you have a low demand variability or certainty, a kanban system can increase your efficiency and reliability while ensuring customer satisfaction.

6 How to combine pull and kanban

You don't have to choose between pull and kanban systems. You can also combine them to create a hybrid system that leverages the strengths of both approaches. For example, you can use a pull system at the strategic level to align your production or service delivery with your customer demand, and use a kanban system at the tactical level to manage your workflow and inventory within your production or service delivery process. This way, you can achieve a balance between flexibility and stability, and between customer value and operational excellence.

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?