CAP Tools for Six Sigma Notes

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The Lean Enterprise
Push versus Pull
Lean Foundations
Continuous Improvement Training
Purpose
The purpose of the module is
to allow you to become familiar with the distinction
between Push and Pull systems.
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Pull and Flow . . . .
Principles of Process Analysis

Flow

Pull Systems
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Actions Required to get improved f - l - o - w
 Batch Size
 Reduce Set-Up times and cut lot sizes
 “Fewer piece flow” - 1 piece is usually better
 People
 Multiple Skill Development
 Multiple Process Handling
 Materials
 Eliminate “Isolated Islands”
 Machines
 Laid out in processing order
 “right” machines to ensure the flow
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Pull and Flow . . . .
Principles of Lean Thinking
Flow
Pull
Systems
PUSH vs. PULL SYSTEMS
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Push vs Pull: What IS the Difference ?
A requirement of any production operation is to
enable everyone to know exactly:
- what product is needed
- by when
- in what quantity
There are two ways to do it:
Here’s One Way - issue PRODUCTION SCHEDULES
to every process using the parts from one process
to drive the work at the next process - in essence
PUSHING THE PARTS THROUGH THE SYSTEM
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Push vs Pull: What IS the Difference ?
A requirement of any production operation is to
enable everyone to know exactly:
- what product is needed
- by when
- in what quantity
There are two ways to do it:
ONE WAY - issue PRODUCTION SCHEDULES to
every process using the parts from one process to
drive the work at the next process - in essence
PUSHING THE PARTS THROUGH THE SYSTEM
ANOTHER WAY - letting a process withdraw the
parts from a preceding process or PULLING THE
PARTS THROUGH
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Push Systems

Driven by Forecasts

Parts are sent to the next Operation or stored in WIP

The second operation continues even if there is a large
amount of WIP from the first operation

Buffers cover problems

Expeditors push Hot parts
PUSH SYSTEMS HAVE NO
DISCIPLINE ON INVENTORY
More is always better
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Pull Production
The Customer usage rate determines the
production rate in a PULL SYSTEM.
“TAKT TIME” is …
that customer usage rate.
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Pull Production



Establishment of Pull systems
between operations in the same plant
Connection of operations that are at a
distance from each other
Elimination of inter-departmental
scheduling
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Pull Production
Produces only what’s required by the
next operation
 The user withdraws from the producer



Kanbans or Visual Systems signal the
need for more
Everyone sees what’s required
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The Lean Enterprise
Push versus Pull
Lean Foundations
Continuous Improvement Training
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