The Pull System Mystery Explained: Drum, Buffer & Rope With A Computer
- Topics:
- Ordering Systems
- Tags:
- Computer,
- Enterprise Resource Planning (ERP),
- Enterprise Software,
- Manufacturing,
- Production,
- Productivity,
- Software
- Source:
- The Remington Group
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Overview: The article tells that people use the analogies of drums, buffers and rope to explain how to "pull" production through a manufacturing shop. There are numerous images one can use to visualize pulling goods through a plant. Since pull systems are frequently contrasted to so-called "push" systems (i.e., MRP II) in which production is master scheduled to push production from one operation to the next whether needed or not, they are often thought of as merely scheduling or shop floor control tools. In fact, pull systems are much more. In a system which triggers production in backward motion, a system of signals is the means to communicate the replenishment of goods. The signal media in a "classic" Kanban system are cards and containers. The Toyota system utilizes a specifically sized container for each part which cycles back and forth between the producing department and the using department (each may have specific store-keeping areas). Two cards (kanban) are used: a production kanban and a conveyance kanban. These kanban specify the part number, the container capacity and other data. The basic concepts of a pull system are the ideas of small lot production in standard lot sizes (the container) signalled by inventory depletion (the production kanban). For manufacturing companies in which the Toyota Kanban system is culturally cumbersome and with frequent demand fluctuations, there is an alternative. That alternative is to simulate the container and card system with cycle times, lot sizes and the company's automated perpetual inventory system.
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Format: HTML | Date: Jan 2003 | Pages: 1
