Pull Systems

Pulling Demand! Rather Than Pushing It!

What you'll learn

The key elements and concepts of a pull system.  Including one piece flow and kanbans.

The foundational steps involved in implementing a pull system with easy to learn mnemonics that outline methodologies including PULLIT, FLOW and ONEPIECE.

Critical techniques like line balancing and the leveling of production.

How you can manage a pull system effectively.

Basics of a kanban system needed to help manage a pull system including internal kanbans, move kanbans and external kanbans.

One-piece or Single piece flow that will help you reach true Pull.

How you can link together outside organizations to your pull system.

Requirements

There are no requirements or prerequisites for this course. All may enroll.

Description

The Pull Systems Course by Lean Strategies International LLC presents the details of just what a pull system is and why they are so powerful. We walk you through the foundational pieces of information that will prepare you to enhance as well as drastically improve the flow of materials in both your supply chain and in your operations. In a pull system all processes are driven by customer demand. This allows an organization to minimize the need for forecasting and operate without schedule while reducing costs, waste and all the delays that occur in a push system. In this course you will learn:The key elements and concepts of a pull system.  Including one piece flow and kanbans.The foundational steps involved in implementing a pull system with easy to learn mnemonics that outline methodologies including PULLIT, FLOW and ONEPIECE.Critical techniques like line balancing and the leveling of production.How you can manage a pull system effectively.Basics of a kanban system needed to help manage a pull system including internal kanbans, move kanbans and external kanbans.One-piece or Single piece flow that will help you reach true Pull.How you can link together outside organizations to your pull system.

Overview

Section 1: Introduction

Lecture 1 Introduction

Lecture 2 What is a Pull System?

Lecture 3 What is a Push System?

Lecture 4 Pull Systems vs. Push Systems

Section 2: Some Challenges of Producing Items and Information

Lecture 5 Challenges of Producing Materials and Information

Lecture 6 The Dangers of Forecasting Demand

Lecture 7 Managing Product Variety

Lecture 8 Reducing Costs associated with Production

Lecture 9 Excessive Waste in Production

Lecture 10 When to Consider not Pulling

Lecture 11 Getting Started with Pull Systems Introduction

Lecture 12 Establishing commitment to continuous improvement and focus on waste reduction

Lecture 13 Implementing regular team based improvement events

Lecture 14 Measuring your improvements

Lecture 15 Creating a visual organization and 5S

Lecture 16 Quick Changeovers

Lecture 17 Training Multi skilled People

Lecture 18 Cellular Designs

Section 3: Why Choose a Pull System?

Lecture 19 Understanding Material/Information Flow

Lecture 20 What happens if you improve only Information Flow?

Section 4: Getting Ready to Make the Switch From Push to Pull.

Lecture 21 Lead Time Considerations in a Push System

Lecture 22 The Impact of Lean on Lead Time

Lecture 23 The problem with inventory and overproduction

Lecture 24 Why does inventory accumulate in organizations?

Lecture 25 Why is inventory dangerous?

Lecture 26 Push to Pull

Lecture 27 Better understand flow

Lecture 28 Where are your customers?

Lecture 29 Breaking down how flow occurs

Lecture 30 What is Flow?

Lecture 31 Value Streams and Flow

Lecture 32 Requirements to keep things FLOWING

Lecture 33 Overview of Leveling

Section 5: Implementing a Pull System.

Lecture 34 Sequence of Implementation

Lecture 35 Creating an infrastructure to Implement Pull

Lecture 36 Roles for your Infrastructure

Lecture 37 A place for lean

Lecture 38 Improvement Time

Lecture 39 Improvement Meetings and Huddles

Lecture 40 List of Improvement Possibilities

Lecture 41 Where will you find most of your improvements?

Lecture 42 The Kaizen Approach to Improvements

Section 6: 6 Steps to Implement Pull

Lecture 43 Basic Steps to Implement Pull Introduction

Lecture 44 Preparing to Implement Pull

Lecture 45 Understand the Current Process

Lecture 46 Layout equipment in sequence

Lecture 47 Lock in cellular manufacturing

Lecture 48 Work Sequence

Lecture 49 Cell Shapes

Lecture 50 Point of Use Placement within Cells

Lecture 51 Implement Kanban

Lecture 52 Transition to single piece flow

Lecture 53 Cell Shapes

Lecture 54 Point of Use Placement within Cells

Lecture 55 Implement Kanban

Lecture 56 Transition to Single Piece Flow

Lecture 57 Leveling Production (Heijunka)

Lecture 58 Shish-Kabob Production

Lecture 59 Takt Time

Lecture 60 How can a Load Leveling Box Help Level Production?

Lecture 61 Balancing your Lines

Lecture 62 Cross Training

Lecture 63 Quality in a Pull System

Lecture 64 What's the difference between an error and a defect?

Section 7: How do you Manage your Pull System?

Lecture 65 Pull System Management Intro

Lecture 66 Guidelines to follow when using Kanban

Lecture 67 How does Feedback work in a Kanban System?

Lecture 68 What is the purpose of kanban?

Lecture 69 Different Types of Kanbans: Move Kanban

Lecture 70 Different Types of Kanbans: Production Kanbans

Lecture 71 Different Purposes of Kanban

Lecture 72 Transitioning to One Piece Flow Intro

Lecture 73 Initiating One-Piece Flow

Lecture 74 Establishing an Environment for Flow

Lecture 75 ONEPIECE - Steps to implement one piece flow

Section 8: Sharing your Pull System with Suppliers.

Lecture 76 Extending pull to your suppliers Intro

Lecture 77 Improving Delivery Transportation

Lecture 78 Improve how your suppliers load their delivery vehicles

Lecture 79 Increase the number of deliveries per day

Lecture 80 Find the most efficient route of delivery

Lecture 81 What to Do Internally to Help Extend Pull?

Lecture 82 Introduction to Supplier Kanbans

Lecture 83 Use Buffer Inventory to Help Suppliers Transition

Lecture 84 Buffer Inventory

Section 9: Wrapping Up

Lecture 85 Wrapping Up

Lecture 86 Graduation

People looking to learn about Pull Systems and Building to Demand.,Continuous Improvement Practitioners,Lean Enthusiasts,Engineers,Production Control Personnel,Production Planning Personnel,Operations Employees,Business Owners Looking to Improve Their Organization,Toyota Production System Enthusiasts,Quality Personnel,Supply Chain Professionals,Inventory and Inventory Management Professionals