How can you use pull production to create a customer-driven system?

Para criar um sistema orientado ao cliente usando produção pull, primeiro, identifico as necessidades dos clientes através de pesquisas de mercado, feedbacks e análise de dados. Em seguida, aplico metodologias como Lean ou Six Sigma para eliminar desperdícios e melhorar a eficiência operacional. Implemento sistemas de produção pull, onde o fluxo de trabalho é orientado pela demanda do cliente, garantindo que apenas o necessário seja produzido, quando necessário. Isso reduz o excesso de estoque e minimiza os tempos de espera, resultando em maior agilidade para atender às demandas do cliente. Utilizo ferramentas como Kanban para visualizar o fluxo de trabalho e identificar gargalos, permitindo ajustes rápidos conforme necessário.

To use pull production: (1) respond to actual demand, (2) minimize waste and optimize resources, and (3) deliver work just-in-time. Adopting a pull system empowers organizations to create a customer-driven ecosystem, where production aligns precisely with real demand, resulting in efficiency and waste reduction.

Pulling the product for the assembly (internal customer) really provides all challenges across the process chain and external supplier chain. This keeps the entire organisation to run on toes but with highest efficiency. If a system installed and sustained for the goals then it becomes a peaceful journey

Quand on parle flux tendu ou de flux tiré cela implique une restructuration complète de la supply-chain interne et externe de la compagnie et une révision de la conception de ses produits. D'une part, il faut adapter la supply-chain via le DDMRP (Demand Driven Material Resource Planning) qui consiste à mettre des stocks tampons (buffers) qui devront jouer un rôle d'amortisseur face aux variations de la demande. D'autre part, cela consiste à mettre en place la différentiation retardée. Concrètement plusieurs produits vont partager une base produit qui ont la même conception. Seules les dernières étapes seront des phases de personnalisation et qui permettront une réactivité et une agilité face à la demande client.

Pull production is tailor made for the customer needs, reduces the storage costs; eliminates waste and is a “Make to Order” process. However, this needs a good forecast and a greater visibility on the customer needs in advance. This is little difficult in large Chemical refineries or in Continuous production plants. Batch plants are more suitable and can accommodate low customer demand or changes in the production grades. Continuous plants are usually “Make to Stock” and produce single items. Of late these plants too, are designed with more flexibility and can accommodate producing multiple items. With little foresight, supplemented with precise planning, these processes too can adapt to the pull production situation, largely.

Customer-Centric Approach: Pull production aligns perfectly with a customer-centric mindset. By prioritizing customer demand, businesses can tailor their production processes to meet specific requirements, thereby enhancing customer satisfaction and loyalty. In a custom-driven system, each order or request serves as a trigger for production, ensuring that resources are allocated efficiently and products are delivered promptly.

Requirements vary by product - 1. Clear understanding of the product 2. Define and align value for the company and the customer 3. Bill of materials is a must 4. Process steps and work instructions for each stage 5. Know your demand, and plan accordingly with proper scheduling

Pull production is a method used in manufacturing to respond directly to customer demand. Here's how you can use pull production to create a customer drive system Understand customer demand Continuous improvement Kanban system Supply chain integration

Le flux tendu nécessite une compréhension de la demande client et le calcul du temps de cycle pour dimensionner l'outil de production. Ce système est vulnérable en raison de l'interdépendance entre ses composants. Il exige une réactivité face aux imprévus, ainsi qu'un environnement de travail propice à la détection rapide des aléas, grâce aux outils tels que les 5S, le management visuel et la standardisation. De plus, il est crucial de sensibiliser le personnel opérationnel à cultiver une intelligence collective pour résoudre efficacement les problèmes rencontrés, en leur enseignant une méthode structurée de résolution de problèmes. En somme, un système de production tendu vise à mettre en lumière les problèmes afin de mieux les traiter.

The elements of pull production form a comprehensive framework designed to optimize manufacturing processes . This strategy minimizes waste and improves overall efficiency through a series of coordinated practices and tools. Let's delve deeper into each element to understand their significance and application in a pull production system: 1.Clear Understanding of Customer Demand and Value: The foundation of pull production lies in accurately gauging customer demand 2.Identification and Elimination of Non-Value-Added Activities. 3.Smooth and Continuous Flow of Work. 4.Minimization of Batch Size, Work-in-Progress, and Cycle Time. 6.Continuous Monitoring, Measuring, and Improvement

One of the principles of any global manufacturing system is SLT- or Short Lead Time. Push and Pull production system have their pros and cons In order to base your system to a Pull driven; the past trends; a very robust forecast, outlook, balancing front end customer demand analysis vs manufacturing capacity and the back end supply chain readiness to the last component is the key. And it is also expected to provide a realistic outlook to the end customer about when wud he/she be getting the product delivered.

The success of Just in Time principle also largely depends on the Pull system from the customers which eventually helps in managing the quality and optimum inventory levels, by making alternative use of the unnecessary blocked capital.

The few steps to implement production are 1. Collection of data of meeting customer demand as per his requirements in qty and duration 2. Identification of bottlenecks in the process 3. Balancing the process to overcome bottlenecks 4. Reviewing the process for any new bottlenecks from time to time 5. Development of strategy for reducing delivery time. 6. Improving the takt time for faster delivery 7. Implementation of poka yoke to avoid unscheduled delay etc

using pull production for a customer-driven system means aligning production directly with customer demand, using signals like orders and feedback to trigger production, being agile to adjust to demand fluctuations, and continuously improving processes to meet evolving customer needs.

Para implementar a produção pull, é essencial começar com uma análise abrangente do estado atual, mapeando o fluxo de valor, identificando a demanda e o valor do cliente, e medindo indicadores-chave de desempenho. Em seguida, é necessário definir um estado futuro ideal, estabelecendo metas de melhoria e planejando a estratégia de produção puxada. A execução do plano inclui testar o sistema, treinar a equipe e monitorar os resultados. Revisar os resultados, compará-los com as metas e identificar lacunas são passos cruciais, seguidos pela implementação de ações corretivas, ajustes e solicitação de feedback para avaliar e aprimorar continuamente o sistema de produção puxada.

It is totally situational and there are a multitude of interactive variables which impact the process so you cannot generalise. In its most simple form you might be lucky to have a market of customers with identical needs and a fairly consistent level of demand. Then you can apply all the principles of lean and get a near perfect process. Unfortunately the real world is not like that. Customers are a cast of characters who exhibit a spectrum of different needs which can and do change suddenly and without warning. There are competitors who might be able to satisfy some of these variants better than we can and this also might change from day to day. In this case, maybe we apply the law of averages in order to minimise risk. It is never easy.

The implementation of pull production is a transformative process that requires acomprehensive understanding of several foundational elements. These elements ensure that production processes are lean, responsive, and customer-centric. Below, we elaborate on some critical components into what makes pull production effective: 1.Understanding Customer Demand and Value: The cornerstone of pull production is a deep understanding of customer needs. 2.Identification of Value-Added Activities: In the context of pull production, activities are scrutinized to determine whether they add value from the customer's perspective 3.Elimination of Bottlenecks and Delays: Achieving a smooth flow of production. 4.Implementation of Pull Signal Systems.

Assurez une transparence totale, minimisez les stocks, engagez-vous dans l'amélioration continue, et soyez flexibles; collaborez étroitement avec les clients, optimisez le flux de travail, et standardisez les procédures tout en formant une équipe polyvalente. De nos jours, l'IA permet de faire de précises prévisions de la demande. Par exemple, une usine de fabrication de vélos pourrait utiliser l'IA pour prédire la demande et ajuster la production en conséquence, partageant les informations de demande et de stock en temps réel avec toute l'équipe, réduisant le stock de composants à un minimum, et formant les employés à plusieurs postes pour une flexibilité accrue.

Challenges: Uncertain Demand: Fluctuations in customer demand can disrupt production planning. Resistance to Change: Employees may resist transitioning to a pull system. Complex Supply Chains: Managing complex supply chains can pose logistical challenges. Initial Implementation Costs: Transitioning to pull production may require upfront investments Solutions: Forecasting Tools: Use advanced forecasting tools to anticipate and manage demand fluctuations. Employee Training: Provide comprehensive training to ease the transition and address concerns. Collaborative Partnerships: Foster collaboration with suppliers to streamline the supply chain.

In my experience companies who seek to implement Pull Production all at once often fail to create a robust enough supplier network to do so, which can result in stumbles. Demand fluctuations can outstrip supplier capacity leading to shortages in components. Every part is critical if it means production could halt. The solution is to examine the supply base from a lean perspective. This includes not only cost and quality but also minimum and maximum order size, scalability, delivery speed and delivery reliability. Typically you’ll need at least two fully qualified suppliers per component to be robust, which also assists with maintaining leverage in negotiations.

Examples of Pull Production for a Customer-Driven System: 1.Just-in-Time Manufacturing: Producing items precisely when needed to minimize excess inventory. 2.Kanban Systems: Using visual cues like Kanban cards to signal when to replenish stock. 3.Customized Production: Tailoring products based on specific customer orders or preferences. 4.Demand-Driven Planning: Planning production based on real-time customer demand data. 5.Continuous Feedback Loops: Incorporating customer feedback to adjust and improve production. 6.Flexible Manufacturing Cells: Adaptable production units capable of responding to varying demands.

Para exemplo forte nos tempos atuais de "produção puxada", podemos citar a demanda atual por energia solar, sabemos que o mercado de energias renovaveis está em alta devido a forte demanda de transferir as fontes de energias, e reduzir o consumo de combustível Fossil. Atualmente as empresas que conheço que trabalham com vendas de sistemas de energias Solar trabalham com um tempo justo de até 90 dias, pra receber o produto, fabricar as estruturas, instalar, e homologar com a concessionária. Este é um bom exemplo que é pequeno e se vê em grande quantidade. Abraço, fiquem bem e seguros.

Aus meiner Sicht werden viele Probleme einer nicht suf Lean optimierten Fertigung durch die Einführung eines Pull-Systems besondes sichtbar. Es sollten Herausforderungen bei Einführung von Pull-Systemen von jenen von Veränderungen in der Produktion getrennt werden. Gerade die eigentlichen Schritte zur Einführung eines Pull-Systems könnten klarer vorgestellt werden (z.B. Losgrößenbestimmung, ggf Taktung oder je nach Reifegrad Bestimmung der Fertigungsschritte).

Um exemplo clássico de produção pull é a Toyota Motor Corporation, que desenvolveu o sistema Toyota Production System (TPS). Este sistema é baseado nos princípios da produção pull e tem sido amplamente adotado em muitas outras indústrias.

Pull production systems, characterized by their demand-driven approach to manufacturing, are implemented across various sectors to enhance efficiency, reduce waste, and align closely with customer needs. Here are expanded insights into the examples provided: 1.Toyota and the Kanban System: Toyota, recognized as the pioneer of the pull production methodology, specifically through its Toyota Production System (TPS). 2.Dell's Build-to-Order Model: Dell has revolutionized the computer manufacturing industry with its build-to-order model, a prime example of pull production in action. Amazon's Inventory and Distribution Optimization: 3. Amazon employs a sophisticated pull production system to manage its vast inventory network efficiently.

1. Understand customer demand 2. Implement a pull production system 3. Establish a customer order request mechanism 4. Create a flexible production process 5. Develop a just-in-time inventory system 6. Continuous improvement and feedback loop 7. Collaborate with suppliers 8. Empower employees 9. Measure and monitor performance:

I believe Pull system starting from customer demand & Make To Order system The advantage is reducing the waste of inventory => higher cash for business & higher profit margin On the other hand the drawback in reality, is that, complexity of planning & supply to keep the flexibility without high level of inventory is high => it does have a higher margin of risk for line stoppage due to raw material shortage In conclusion, despite Push system starting from customer demand, considering the low level of inventory & recent challenges of supply (red sea, wars, pandemic, & etc) it has higher margin of risk for manufacturing continuity and consequently customer So its starting from customer demand but that's not necessarily customer driven

Pull is a method to align the demand to your internal process. As well, Pull is the forth principle of lean manufacturing strategy. Main goal of the companies implementing lean manufacturing is to reduce, or to eliminate waste in their processes. Implementing lean manufacturing strategy will gerate more real value for the customers.

Pull System = Actual Demand/Quantity at correct Time to reduce uneven inventory and wastages/losses at different stages or processes.

Pull production, where production responds to actual customer demand, can create a customer-driven system in several ways: 1. Focus on actual needs: Only producing what's truly needed eliminates overproduction and waste, aligning with customer demand instead of forecasts. 2. Increased responsiveness: Responding directly to orders allows quicker adjustments to product variations or volumes, meeting evolving customer preferences. 3. Reduced lead times: Faster production cycles mean shorter wait times for customers, improving their satisfaction and experience. 4. Continuous feedback: Pull systems encourage communication with customers, providing valuable insights for product improvements and future orders.