Pull Systems

Pull and visual scheduling systems help organizations to realize dramatic gains in the velocity of work flow, reduced inventory, improved visibility of operational status, and improved synchronization of the diverse processes that must be coordinated within a value stream. An abbreviated version of this course is available for your front line personnel. In this class, hands-on simulations show them how pull systems work and are used to explain their role to day-to-day support of pull systems. A more comprehensive course is available for teams charged with design and implementation of pull and visual scheduling systems in your organization. This course, typically two days in duration, is built around a series of simulations, design exercises, and case studies. It vividly illustrates and explains the theory of pull systems and pull/MRP integration, presents and applies a practical procedure for design of these systems, and describes good operational practices to support production control, visual scheduling, and your complementary internal logistics systems.

Numerous exercises are employed throughout this class to support learning. They include:

• A hands on simulation that illustrates the fundamental mechanics of pull systems, including blocking,
• Dispatching, feeder-line synchronization, route-specific versus part-specific structures, pull/scheduling interfacing, and pacemaker concepts.
• Discovery learning exercises where students develop and operate various types of basic pull systems, including one-card and two card systems, supplier kanban systems, supporting logistics systems, and electronic-kanban systems.
• Several CONWIP (CONstant Work In Process) pull simulations that address fundamental operational principles of CONWIP, the utility of CONWIP in high work-content-variability applications, and design principles for structuring CONWIP systems for manufacturing and service applications.
• A design exercise for structuring a CONWIP system for a real world manufacturing facility.
• A comprehensive design exercise where students configure a complex pull system and then implement and operate that system.

Students who take this class will learn…

• The basic principles of pull systems from both a production control and managerial perspective
• The difference between part-specific and route specific systems and when to use each type
• The pacemaker concept and its role in value stream restructuring
• Leveling criteria and procedures, including methods that can be executed by shop floor personnel
• Integrating pull with scheduling systems Buffer sizing principles and calculations
• The pros and cons of CONWIP, when it should be used, and designing the structure of CONWIP systems for practical applications
• Logistics approaches, including kitting and staging strategies, that support effective operation of pull systems
• Visual scheduling approaches to support dispatching, sequencing, and status response decisions.
• Systematic procedures for designing pull systems