登录查看更多内容

How do you manage quality and waste reduction in a pull system process?

由人工智能和领英社区提供技术支持

A pull system is a lean process improvement method that aims to reduce waste and improve quality by producing only what the customer demands, when they demand it. Unlike a push system, which makes products based on forecasts and inventory levels, a pull system relies on signals from the downstream process to trigger the upstream process. This way, the production flow is synchronized with the customer demand, avoiding overproduction, excess inventory, and waiting time. However, managing quality and waste reduction in a pull system process is not without challenges. In this article, you will learn how to overcome some of the common obstacles and optimize your pull system process.

此文章中的业界达人

由社区从 3 条内容中精选。了解更多

Amy Redekar

Senior Stock & Supply Chain Planning Manager

1 Define your value stream

The first step to manage quality and waste reduction in a pull system process is to define your value stream, which is the sequence of activities that deliver value to the customer. You need to map out the current state of your value stream, identifying the inputs, outputs, resources, and wastes of each process. Then, you need to design the future state of your value stream, eliminating or minimizing the non-value-added activities and improving the value-added ones. This will help you create a smooth and efficient flow of products and information from the supplier to the customer.

添加您的观点

Amy Redekar

Senior Stock & Supply Chain Planning Manager
举报内容
Absolutely. Value stream mapping is essential. Transformational projects would typically seek support from lean specialists/consultants.

已翻译

赞

2 Implement pull signals

The second step to manage quality and waste reduction in a pull system process is to implement pull signals, which are the triggers that communicate the demand from the downstream process to the upstream process. There are different types of pull signals, such as kanban cards, electronic signals, visual cues, or containers. The key is to choose the most appropriate pull signal for your process, considering the complexity, variability, and frequency of the demand. The pull signal should be clear, simple, and visible to all the involved parties, and it should indicate the quantity, quality, and timing of the production.

添加您的观点

3 Control the work in progress

The third step to manage quality and waste reduction in a pull system process is to control the work in progress (WIP), which is the amount of unfinished products or materials in the process. WIP is a form of waste that consumes space, resources, and capital, and it can cause defects, delays, and overproduction. To control the WIP, you need to set limits on the number of pull signals or the amount of inventory that can be in each process stage. This will prevent the upstream process from producing more than the downstream process can consume, and it will create a balance between supply and demand.

添加您的观点

4 Monitor and improve the process

The fourth step to manage quality and waste reduction in a pull system process is to monitor and improve the process, using data and feedback to identify and eliminate the root causes of problems. You need to measure the performance of your pull system process, using metrics such as cycle time, throughput, lead time, quality, and customer satisfaction. You also need to collect and analyze the data from the pull signals, such as the frequency, quantity, and quality of the demand. Based on the data and feedback, you need to implement corrective and preventive actions, such as standardizing the work, eliminating defects, reducing variation, and increasing flexibility.

添加您的观点

Amy Redekar

Senior Stock & Supply Chain Planning Manager
举报内容
Lean methodologies focus on best practice and continuous improvement. For example a Kanban system with reliable inputs provides data, which can be analysed to determine a particular bottleneck in the process or single points of failure. Corrective actions could look like, adding more resource to work through the queue more quickly or revise a process to improve the inputs at the start of the process (in turn providing better outputs). Focusing on getting the inputs right first time (RFT) can speed up the process, and eliminate repetition of the same task/s (second or third time round). I would suggest further reading on LeanKit or Kanbanize tool kits.

已翻译

赞

5 Empower your team

The fifth step to manage quality and waste reduction in a pull system process is to empower your team, which is the people who perform the value-added activities in the process. You need to involve your team in the design, implementation, and improvement of the pull system process, giving them the authority, responsibility, and autonomy to make decisions and solve problems. You also need to train your team in the principles and practices of lean process improvement, such as customer focus, continuous improvement, waste elimination, and value creation. By empowering your team, you will increase their motivation, engagement, and ownership of the process.

添加您的观点

加载更多内容

6 Align with your customers and suppliers

The sixth step to manage quality and waste reduction in a pull system process is to align with your customers and suppliers, which are the external parties that influence and are influenced by your process. You need to communicate and collaborate with your customers and suppliers, understanding their needs, expectations, and feedback. You also need to align your pull system process with their requirements, capabilities, and constraints, ensuring that you deliver the right products, at the right time, at the right quality, and at the right cost. By aligning with your customers and suppliers, you will increase their satisfaction, loyalty, and trust.

添加您的观点

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?

添加您的观点

Lean Process Improvement

+ 关注

给文章评分

我们借助人工智能创建了此文章。您认为这篇文章怎么样？

很棒不太好

举报此文章

查看全部

How do you manage quality and waste reduction in a pull system process?

1

2

3

4

5

6

7

1 Define your value stream

2 Implement pull signals

3 Control the work in progress

4 Monitor and improve the process

5 Empower your team

6 Align with your customers and suppliers

7 Here’s what else to consider

Lean Process Improvement

给文章评分

感谢您的反馈

更多Lean Process Improvement相关文章

更多相关阅读内容