[Chapter 9]

[Principle 3: Use “Pull” System to Avoid Overproduction]

The concept

“The more inventory a company has,…the lesslikely they will have what they need.”

- Taichi Ohno

The Principles

Customer pull and replenishmentFlow where you can, Pull where you must

Push system

Pull system

Pull – Replenishment in Everyday Life

Fill every Monday morning ?

Schedule

Just in time replenishment Using Kanban – monitoring and coordinating

Pull – Replenishment in Everyday Life

Ideal SystemSingle Piece Flow Continuous – No Inventory

Supplier

TOYOTA Factory

Finish Good

Body shop

Welding

Painting

Final assembly

Toyota’s Kanban SystemWhat is the Kanban system?

Kanban is the method of production authorization and materials movement in the JIT system.

• In Japanese means sign, sign card or marker.

• Scheduling system to aide in process flow.

• Kanban can be flexible, but tends to follow a basic pattern.

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Kanban Method• Visualize the workflow• Limit work in process (WIP)• Manage flow• Make process policies explicit and improve collaboratively

Toyota’s Kanban System

Supplier

Body Factory

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Final assembly Factory

Dealer

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Order- 2 Altis- 1 Yaris

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FG

Push Scheduling Has Its Place

Using Pull in a GM Office

When a certain soft drink gets to a certain level, Take the KANBAN for that soft drink and put it in a box so it will get reordered.

Using Pull in a GM Office

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