Incremental:
The Continuous Improvement Podcast Episode 11. Push, Pull, and Flow
Mar 22, 2023
Discover the nuances of push, pull, and flow manufacturing, key elements of the Toyota Production System. Learn why overproduction can be wasteful and the financial impacts of excess inventory. Explore innovative tool management strategies using Kanban for timely replenishment. Uriel and Devin share lessons on improving internal communication and workplace safety, emphasizing the importance of respect for employees. Plus, insights on minimizing batch sizes and optimizing shop processes for continuous improvement are revealed.
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Push Versus Pull Production
- Push systems produce large batches based on schedule rather than current demand, creating overproduction waste.
- Pull systems trigger production in response to consumption, matching replenishment to actual usage to reduce inventory waste.
Kanban Keeps Inventory Aligned
- Pull uses Kanban triggers to replace stock as it gets consumed, keeping inventory aligned with demand.
- Even in pull, some inventory between processes is often required due to practical constraints on perfect flow.
Cut Motion By Reducing Prep Batches
- Eliminate unnecessary intermediate handling by designing stations so parts move directly to the next process.
- Reduce batch-and-store prep by placing small prep stations near use points to cut motion and waste.
