Step 6 – Pull System

Lean Expert Training Online

Welcome to lesson eight in the Level 3 – Lean Expert Training Course.

To see detailed instructions explaining how to watch the videos and download any attached files or documents for this lesson…click here.


Lesson 308 – Step 6 Implement a Pull System

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In the Level 2 – Lean Practitioner training course you learned how Step 6 – Implement a Pull System is focused on visual control of work in process (WIP) and inventory. A critical element of any “Just in Time” system is to ensure everything that is needed is available, in the right place, at right time, every time!

You learned that the number one cause of process downtime are changeovers or set-ups that force the operation to stop and start up again. You also learned that one minute of downtime is equal one minute of lost production time!

In the Level 3 – Lean Expert training course, you will learn about the detailed application and integration of Step 6 – Implement a Pull System as part of a continuous process improvement methodology.

Transformation requires a plan and an infrastructure that is focused on waste reduction to improve value for the customer. It also requires a strong management team that is willing to support the process because the right kind of change does not happen by chance!

In Step 5 – Reduce Changeover Times, you learned to recognize and reduce one of the major process constraints that impedes flow. In this next step, you will learn how to control the scheduling of inventory replenishment through the use of visual controls.


Lesson 308-1: Introduction to Step 6 Implement a Pull System (4:16) In this introduction video, Chris Turner gives an overview of the Level 3 – Lean Expert Step 6 Implement a Pull System training materials, and he explains why they are integral part of the 10 Step training and implementation process – 

Lesson 308-2: Step 6 Implement a Pull System Part 1 (17:10) – 
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To download the documents for Step 6 Part 1…click here

Lesson 308-3: Step 6 Implement a Pull System Part 2 (24:12) – 
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To download the documents for Step 6 Part 2…click here

Lesson 308 – Additional Learning Resources

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Throughout the Lean Expert course we try to share relevant information that gives a practical example of the application of the lean tools and techniques presented in the training materials.

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Video 1: In this video by the Lean Academy, you can see a live example of batch and queue production versus one piece flow production (3:36) – Click here to view video

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Video 2: In this video by LeanCor3PL, you can see a live example of a pull system using kanban to replenish production materials (2:07) – Click here to view video

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Video 3 Here is a video called “Stockless Production.” This video is a documentary produced in 1983 by Hewlett-Packard to demonstrate the manufacturing improvements that can be realized by implementing of a pull system using kanban. The pricniples are the same as those seen in the previous, more modern videos (28:35) – 

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