Pull Systems are another very important Lean Manufacturing concept. Traditional manufacturing used the “push” concept, making large batches of product and “pushing” them to each downstream operation whether they are ready for them or not.

Push systems also often have products produced that are not sold.

Ideal Pull Systems start at the opposite end, the customer, and once the customer signals an order, that last process signals to the upstream process to produce product. Each upstream process receives the signal (order) from the downstream process that it needs product, all the way back to the supplier of raw material.

Idea pull systems do not produce to inventory. Lean manufacturing concepts teach why inventory is one of the largest wastes in a company. Inventory costs money to purchase which raises the working capital necessary to run a business. The excess working capital necessary forces the company to either use its cash for inventory or raises borrowing amounts. Excess inventory often results in inefficient operations from having it in the way. Inventory often becomes obsolete having to be “written off” or sold at a loss or a lower price.

It is imperative that companies embarking on a pull system understand and employ lean manufacturing concepts as they apply to their manufacturing process. Concepts such as “kanban” often need to be utilized to keep the flow in a pull system.

If a company employs a pull system prior to being ready for the change, it will incur additional costs from down time and higher per unit costs.

Our Lean Manufacturing on line course teaches the pull system and how it applies in the manufacturing setting. The course includes all of the lean concepts because they must all be understood to apply lean effectively.

BPR’s lean manufacturing certification online courses can be completed at your convenience 24/7. Simply log in and begin the course. You can stop any time and come back to where you left off. Once the course is successfully completed, the certification will be mailed to you.