Nov 12, 2008

Push and pull system 1

Today my good partner Mr. Steed Wei told me a good trope of the phenomena between pull and push system. I would like to share with my reader.
In mass production world, push system is using for the processes. The trope is like a long chain of safety pins, fixed one end and push from another end. What will happen? all safety pins pushed and mess together. Every safety pin represented one individual process. If a push system apply on the continuous process, we can find there is so many raw material, WIP all mixed and idle between the process stations. Just like the chain of safety pins mess together and pin cover by another pins. You can not identify the problem in such mess situation.
In lean production world, pull system is using for the processes. Just like the safety pins fixed one end and pull from another end. The safety pins will attach and pull in sequence. That's meant all processes are well assigned in order. No raw material and WIP idle between them. The most important thing is we can identify all the problem in every process. Please remember that the important principle of lean manufacturing is PROCESS FOCUS, and that's why we need to apply pull system to show us the problem between or on the processes.
On the road from PUSH to PULL, we can find a lot of problems and that is what we want to identify for further improvement. However, the responsible members are always not understand the destination of the system. They always rise so many opposite excuses to go back to the original way of working because they have more buffer in push system. The leader of lean transformation like us needs to well explain the team for what is the expected outcome and encourage them for further improvement.
Actually, I faced the same situation right now. Do you have the same problem?

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