Pull Production for the Shopfloor

124 Pages·2002·4.633 MB·English

by  Productivity Press Development Team

Pull Prod./front matter 4/17/2002 3:42 PM Page i
Pull Production
for the Shopfloor
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SHOPFLOOR SERIES
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Pull Production
for the Shopfloor
CREATED BY
The Productivity Press
Development Team
Productivity Press • New York
CRC Press
Taylor & Francis Group
6000 Broken Sound Parkway NW, Suite 300
Boca Raton, FL 33487-2742
© 2002 by Taylor & Francis Group, LLC
CRC Press is an imprint of Taylor & Francis Group, an Informa business
No claim to original U.S. Government works
Version Date: 20130222
International Standard Book Number-13: 978-1-4665-3030-0 (eBook - Kindle)
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Contents
Publisher’s Message ix
Getting Started xi
The Purpose of This Book xi
What This Book Is Based On xi
Two Ways to Use This Book xii
How to Get the Most Out of Your Reading xii
An Overview of the Contents xiv
Chapter 1. Choosing Pull Production 1
The Context for Pull Production 2
What Is Pull Production? 4
Two Aspects 4
Pull versus Push 4
The Challenges of Production 5
The Problem of Forecasting Customer Demand 5
Small-Lot, Wide-Variety Production 5
Cost Reduction 6
Waste 7
When Pull Might Not Be the Goal 7
The Prerequisites of Pull Production 8
An Awareness of Waste and Commitment to the Principles of
Continuous Improvement 8
Team-Based Improvement Activities 8
Process Measures 8
5S—Visual Order, Displays, and Signals 8
Quick Changeover Activities 9
A Multi-Task Trained Workforce 9
Cell Design 9
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CONTENTS
The Benefits of Pull Production 11
Company Benefits 11
Individual Benefits 11
In Conclusion 12
Summary 12
Reflections 13
Chapter 2. Understanding and Preparing for
Pull Production 15
Approaches to Production Management 16
What Is Production Management? 16
What Is the Significance of Lead Time? 17
How Does Lean Production Impact Lead Time? 19
The Problem with Stock and Overproduction 21
Why Does Inventory Accumulate? 21
Why Is Inventory Bad? 22
Push versus Pull Production 24
Production Is Music 25
The Next Process Is Your Customer 26
Stop and Go versus Process and Go Production 27
What Is Flow Production? 28
The Value Stream 28
Seven Requirements for Flow 29
Leveling 30
Implementation Sequence 30
In Conclusion 32
Summary 32
Reflections 34
Chapter 3. Implementing Pull Production 35
The Improvement Infrastructure 36
Key Roles 36
The Promotion Office 37
Improvement Days 37
Improvement Meetings 37
An Improvement List 38
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CONTENTS
The Factory Floor 38
Kaizen Events 38
Five Steps to Pull Production 39
Step One: Identify the Current Process 39
Step Two: Co-Locate Equipment in Sequence 40
Step Three: Design Manufacturing Cells 42
Step Four: Initiate the Kanban System 46
Step Five: Shift to One-Piece Flow 47
Level Production 48
Shish-Kabob Production 49
Takt Time 50
The Load Leveling Box 51
Line Balancing 51
Cross-Training 53
Quality Systems 53
Levels of Quality 53
Errors versus Defects 54
In Conclusion 55
Summary 55
Reflections 57
Chapter 4. Managing Pull Production 59
The Rules of Pull Production with Kanban 60
Feedback with the Kanban System 60
Functions of Kanban 61
Types of Kanban 63
How the Kanban System Works 64
How Many Kanban Do You Need? 65
An Analysis of Pull Production 66
When Do You Pull? 66
Where Do You Pull From? 66
What Do You Pull? 67
What Do You Produce? 68
One-Stage versus Two-Stage Pull Systems 69
Supermarkets 69
Water Beetles and Milk Runs 70
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CONTENTS
In Conclusion 73
Summary 73
Reflections 75
Chapter 5. Extending Pull Production 77
Establishing One-Piece Flow Production 78
Seven Conditions for Flow 79
Steps to Achieve One-Piece Flow 80
Using Moving Lines and Feeder Cells 81
Linking Suppliers to the Pull System 83
Changes in Transport Methods 83
Changes in Delivery Sites 85
Supplier Kanban 87
Buffers 89
Challenges, New Thinking, and Success Factors 90
In Conclusion 91
Summary 91
Reflections 93
Chapter 6. Reflections and Conclusions 95
A Summary of Pull Implementation 96
Reflecting on What You’ve Learned 97
Opportunities for Further Learning 98
Conclusions 98
Additional Resources Related to Pull Production 99
Books and Videos 99
Newsletters 101
Training and Consulting 101
Website 101
About the Productivity Development Team 102
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Publisher’s Message
Pull Production for the Shopfloor is the fourteenth book to be
published in the Shingo Prize-winning Shopfloor Series by
Productivity Press. We have presented books on 5S, cellular
manufacturing, quick changeover, mistake-proofing, just-in-time,
kaizen, kanban, and several on TPM (including autonomous
maintenance, focused equipment improvement, and overall
equipment effectiveness). When you implement pull production,
the various lean methodologies you have already learned and
implemented unite to become a powerful totality for achieving
and sustaining lean manufacturing. Before implementing pull
production, you will want to have achieved a solid level of profi-
ciency in several lean methods. But once you are ready for pull,
this book will give you the process for getting there, and will
present it to you in an easy-to-read-and-assimilate format.
Throughout the book, you will be asked to reflect on questions
to help you apply pull implementation to your workplace.
Numerous illustrations will reinforce the text.
The introductory section, “Getting Started,” will suggest reading
and learning strategies, explain the instructional format of the
book, and give an overview of each chapter. Chapter 1 presents
the context for choosing pull production. To help you under-
stand and prepare for pull, Chapter 2 discusses production man-
agement, stock and overproduction, push versus pull, and the
requirements for achieving flow production. Chapter 3 tells
how to establish an improvement infrastructure and takes you
through the pull implementation process, step by step. Chapter 4
explains how to manage pull production with the kanban system.
Chapter 5 discusses one-piece flow and advises how to bring
suppliers into your pull process. Finally, a summary of the phases
for implementing pull and resources for further learning are
presented in Chapter 6.
In today’s market, manufacturing companies will not survive with-
out the ability to manage wide-variety, small-lot production while
keeping costs down. Pull production gives you that capability.
This book will show you how to bring your various lean efforts
together to achieve pull production.
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