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The pull system is often called the kanban system by many people.
In the Traditional production system the exact customer order regardless of size is pushed from first area to the next until we have a completed production order.
Lets look at what a pull system looks like starting with the customers order going to shipping
A completed parts store is always located at the end of the producers line site so that they may see what is being pulled and avoid the delay in the kanban reordering. Contains all varieties of completed parts Quantity of completed products Lot size of production Frequency of withdrawal
It is important to not over load the line site with too much product and we should avoid production people from having to leave the work area to get stock
The idea system is paced with regular smooth withdrawals
The larger the lot size, the larger our inventory hoding cost is. Changeover cost go down as the lot size increases but the but the over all total holding cost goes up.
As we reduce our lot sizes, our inventory cost goes down Our changeover cost do go up but over all cost go down This is the main reason for added pressure on reduced change over times not so that we can improve the efficiency of our equipment but so we can reduce our lot sizes.
As set up time is reduced, the total amount of machine change over is increased
These are the basic rules to follow when implementing a kanban system
These increased machine change over times aids in the leveling of production orders. Toyota tries to take every customer order and break it down into smaller manageable orders. This is the secret to handling different customer order volumes on a daily basis.
Level loading is the Lean production method to use customers orders to establish a production rhythm.