Push and Pull Production Systems - The Magic of Pull

4 important questions on Push and Pull Production Systems - The Magic of Pull

How does a WIP cap in pull reduce manufacturing costs?

Since releases are choked off text-decorationbefore the system can get overloaded, costs related to "undo" this overloading (such as expediting, overtime and engineering changes) are minimized.

Why does Kanban achieves less variable cycle times than a pure push system?

Since cycle time increases with WIP level (Little's law), and kanban prevents WIP explosion, it is also prevents cycle time explosions.

1: How is low variability a prerequisite for pull?

2: How is low variability an effect of pull?

 

1: By limiting the WIP, th system is more vulnerable to variability ("water and rocks" analogy), so low variability is a prerequisite for pull to work well.

2: By putting a WIP cap, WIP & CT explosions are prevented, which leads to less variable cycle times.

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Which main five operational benefits are often attributed to pull?

  1. reduced manufacturing costs
  2. reduced variability
  3. improved quality
  4. high flexibility
  5. the ability to (slightly) work ahead (when all goes well)

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