• A Pull System is a manufacturing process in which production is initiated in response to customer demand, rather than in anticipation of customer demand. In a pull system, each step in the manufacturing process produces only the quantity of products that are required by the next step in the process, based on customer demand. This creates a flow of materials and products through the manufacturing process that is driven by customer demand, rather than by internal production targets.

• In contrast, a Push System is a manufacturing process in which production is initiated based on internal production targets, rather than customer demand. In a push system, each step in the manufacturing process produces a fixed quantity of products, regardless of whether there is customer demand for those products. This can create a situation where excess inventory builds up in the manufacturing process, leading to waste, inefficiencies, and increased costs.

• The main difference between a pull system and a push system is the direction of production flow. In a pull system, production is driven by customer demand, which creates a flow of materials and products through the manufacturing process. In a push system, production is driven by internal production targets, which can create a backlog of inventory and disrupt the flow of materials and products through the manufacturing process.

• Pull systems are a key component of lean manufacturing, as they help to reduce waste and improve efficiency by aligning production with customer demand. By using pull systems, manufacturers can avoid overproduction, reduce inventory, and improve product quality, while also delivering greater value to customers.

• Kanban is a visual system for managing inventory and production, which uses signals such as cards or bins to trigger the production of a particular item.

  • The word "kanban" means "signboard" or "visual signal" in Japanese, and the system is designed to provide a visual representation of the flow of materials and products through the manufacturing process.

  • By using kanban, manufacturers can ensure that they produce only what is needed, when it is needed, and in the quantity that is needed.

• Kanban systems typically utiilze physical cards, bins, or other visual signals to communicate information about the production process, such as the status of inventory levels, the need for raw materials, or the production status of a particular item.

  • Kanban is important because it helps to ensure that the manufacturing process is aligned with customer demand, and that products are produced only when they are needed, in the right quantities, and with minimal waste.

• Kanban can be practically utilized in a number of ways, depending on the specific needs of the manufacturing process.

  • Some common ways that kanban is used in lean manufacturing includes:

    • Inventory management: Kanban can be used to manage inventory levels by using signals to indicate when inventory is running low and needs to be replenished. This helps to ensure that inventory levels are optimized and that excess inventory is not produced.

    • Production scheduling: Kanban can be used to schedule production by using signals to indicate when a particular item needs to be produced. This helps to ensure that production is aligned with customer demand, and that excess inventory is not produced.

    • Quality control: Kanban can be used to monitor quality by using signals to indicate when a particular item has been inspected and approved for shipment. This helps to ensure that products are produced to the highest quality standards and that customer satisfaction is maintained.

    • Continuous improvement: Kanban can be used to support continuous improvement by providing a visual representation of the manufacturing process and identifying areas for improvement. By using Kanban to track and analyze the flow of materials and products through the manufacturing process, manufacturers can identify bottlenecks, inefficiencies, and opportunities for improvement.

• Overall, Kanban is an important tool for lean manufacturing that helps to ensure that the manufacturing process is aligned with customer demand, and that products are produced efficiently, with minimal waste and inventory.

  • By using Kanban to manage inventory, schedule production, monitor quality, and support continuous improvement, manufacturers can optimize their processes and deliver greater value to customers.

• Level-Loading is a lean manufacturing strategy that aims to smooth out production schedules by producing a consistent amount of output over a given period of time, rather than producing in batches or in response to fluctuations in demand.

  • It originates from the Japanese term "Heijunka", which translates to "leveling"

  • The goal of level-loading is to create a consistent and predictable production process that is better able to meet customer demand, while also reducing waste and improving efficiency.

• Level-loading is important because it helps to reduce the costs associated with fluctuations in demand, such as the cost of overtime or the cost of excess inventory.

  • It also helps to improve customer satisfaction by ensuring that products are delivered on time and in the quantities required.

• Level-loading can be practically done in a number of ways, depending on the specific needs of the manufacturing process. Here are some common ways that level-loading is used in lean manufacturing:

  • Mixed-model production: Mixed-model production is a technique for producing a variety of products in small quantities, rather than producing in large batches. This can help to smooth out production schedules and reduce the costs associated with fluctuations in demand.

  • Cross-training: Cross-training employees to perform multiple tasks or work across multiple workstations can help to improve flexibility and reduce the impact of absenteeism or fluctuations in demand.

  • Standardized work: Standardizing work processes and procedures can help to create a consistent and predictable production process that is better able to meet customer demand.

• Overall, level-loading is an important tool for lean manufacturing that helps to create a consistent and predictable production process, reduce waste and inefficiencies, and improve customer satisfaction.

2.3✔ CHECKPOINT

Airplane Boarding - Level-Loading