What Different Pull Systems Can Be Combined?

In my last few posts I have shown you different ways to establish pull systems, and which one is right for you. This post discusses how you can mix and combine these systems. You can combine some pull systems within the same pull loop, although there are some restrictions. Combinations of different kanban systems are very common, often also including a CONWIP system.

You can also combine different pull systems for sequential loop, where for example a kanban system feeds into a CONWIP system. This blog post is loosely based on chapter 3.3 and 11.1.7 of my new book All About Pull Production: Designing, Implementing, and Maintaining Kanban, CONWIP, and other Pull Systems in Lean Production.

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Which Pull System Is Right for You?

In my last few posts I showed you different types of pull systems, and an overview of the criteria on how to decide which one is right or you. In this post I finally give you a hands-on guide to decide which pull system to use. This blog post is loosely based on chapter 3.2 of my new book All About Pull Production: Designing, Implementing, and Maintaining Kanban, CONWIP, and other Pull Systems in Lean Production. Let’s have a look:

This is a cross post with the same article on Planet Lean.

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What Are the Criteria to Decide on a Pull System?

There are different ways to establish a pull system. In my last post I gave an overview of the different types of pull system. Before telling you which one to use when I want to show you the different factors that should go into your decision. What do you have to pay attention to if you want to select a pull system? This post is loosely based on chapter 3.1 of my new book All About Pull Production: Designing, Implementing, and Maintaining Kanban, CONWIP, and other Pull Systems in Lean Production. Let’s have a look:

This is also a cross-post with the same article on Planet Lean.

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The Different Ways to Establish Pull Production

Kanban is the best known way to establish pull production. But it is not the only way. There are many different methods to create a pull system. This blog post is loosely based on my new book All About Pull Production: Designing, Implementing, and Maintaining Kanban, CONWIP, and other Pull Systems in Lean Production, which is a practical guide for anyone looking to implement pull systems. Let me give you an overview.

This is a Cross-Post with the (almost) identical article 7 tools to establish pull production on Planet Lean.

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What Is a Good Minimum for the Supermarket?

An empty standard EUR pallet
Prevent a stock out!

A minimum level in a supermarket gives you a warning that a stock out is imminent. Hopefully it also gives you enough time to prevent such a stock out, even though this may result in firefighting. In my last post I talked on how to use a minimum level. This post will look at how to determine a good minimum level.

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How to Use a Minimum in a Supermarket

Warning: Toilet Paper Stock Out Imminent!
Warning: Toilet paper stock out imminent!

The kanban formula (or estimation) helps you determine the number of kanban. All of these should fit in the supermarket, hence the maximum in the supermarket represents all kanban. Many supermarkets also have a minimum inventory level. Unfortunately, there is little information on how to set the minimum. Time to take a deeper look on how to set and use the minimum level in the supermarket. In this first post I will look at how to use a minimum level in a supermarket. The next post will look at how to determine a good minimum level.

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Toyota’s Six Rules for Kanban

Simple Kanban LoopThe kanban system is the most famous way to establish a pull system. As part of their guidelines for kanban, Toyota has established Six Rules for Kanban. They can be found, for example, in the 1973 Toyota Production System Handbook. This blog post describes these six rules, based on the Toyota handbook. While these rules are all true, they are in themselves not sufficient to establish a kanban pull production. Nevertheless, this post will show you these six rules.

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When and How to Use Extra Kanban

Dog with bandage and first aid kitKanban (and pull systems in general) are a beautiful way to manage production. While the number of kanban cards should be verified periodically, for certain situations, however, it may be sensible to have additional kanban prepared. These extra kanban are added to the system on short notice to alleviate symptoms of other problems. However, please do not see this as a new and cool additional feature to your kanban system. Instead, if you have to use extra kanban, then something is going  wrong. Such extra kanban are only an emergency fix and do not solve the underlying problem. Still, in some cases you do need an emergency fix. Let me explain:

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