Understanding Pull Systems in Manufacturing

Lean manufacturing focuses on minimizing waste by aligning production with actual customer demand, using pull systems. These systems, including sequential and replenishment types, limit work-in-process inventory and rely on real-time signals to manage production. Kanban cards are used to signal supply needs, enhancing task prioritization and preventing overload. Examples illustrate how pull systems operate in manufacturing environments, ensuring efficient workflow and resource use.

What is the primary goal of lean manufacturing?

• To increase inventory levels

• To reduce or eliminate waste

• To forecast future demands

• To maximize production speed

In a pull-based system, production is primarily driven by:

• Market trends

• Actual customer orders

• Historical data

• Forecasts

What is a key characteristic of a pull system?

• It is forecast-driven

• It relies on large inventories

• It is control-oriented and signal-based

• It operates without any signals

Which type of pull system involves downstream personnel pulling parts in sequence?

• Replenishment pull

• Random pull

• Sequential pull

• Batch pull

What is the ideal output in a sequential pull system?

• High inventory levels

• One-piece flow

• Large batch production

• Randomized production

Replenishment pull systems are also known as:

• Warehouse systems

• Supermarket systems

• Batch systems

• Forecast systems

What tool is commonly used in replenishment pull systems to signal the need for more supplies?

• Production schedules

• Forecast charts

• Kanban cards

• Inventory lists

In the context of pull systems, what does Kanban mean?

• A production schedule

• A signal for production

• A storage location

• A type of inventory

What happens when a sub-assembly is removed in a pull system example?

• The operator replenishes the sub-assembly

• The operator waits for instructions

• The production stops

• The inventory is increased

In a pull system, when is action triggered?

• When the forecast is updated

• When the whip limit is reached

• When the inventory is full

• When the production schedule is set