Very often you will be faced with the situation when implementation of continuous flow in the whole process, from raw materials to finished goods, is not possible. There are ?gaps? between processes where there is no flow. This points can quickly become an areas where inventories accumulate and FIFO is gone. TO avoid such an situation you need to implement clear rules of flow management based on pull system principles. Pull system allows to eliminate overproduction and inventories through giving clear instruction to upstream processes what, when and how many to produce. The practical realization of pull principle must be tailored to specific situation of each and every process: it can be just a simple two-bin system or sophisticated bar-code controlled Kanban system.

During the training principles of pull system will be described as well as guidelines and practical tools for implementation. By doing a Kanban simulation participants will get to know how to design a pull system, what to look for and what are potential threads for its effective work.

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Expected Training Results

At the completion of a training participants will be able to:

  • Identify the threads connected to overproduction and inventory
  • Know when implementation of pull system is relevant
  • Use Lean tools to create material management system
  • Design pull system
  • production management
  • process design
  • logistics
  • parts delivery

Training Plan


Problems with planning and control of material flow lecture + discussion + examples
Pull flow: basic principles, flow control, designing the system and continuous improvement lecture + discussion + examples
Managing internal flow (inbound logistics): material delivery (JIT,JIS, milkrun), transport means, basics of warehouse management lecture + examples
Kanban simulation ? designing of pull system simulation
Managing external flow (outbound logistics): supply strategy, purchasing strategies, warehousing, external transport lecture + discussion + examples
Training summary discussion