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Source Book: Factory Physics (Hopp & Spearman, Source Book: Factory Physics (Hopp & Spearman, 2000)

This document contrasts push and pull production systems and discusses implementing pull systems in practice. It explains that push systems trigger work from outside the system based on forecasts, while pull systems trigger work from inside the system based on downstream demand. Push systems can lead to overloaded stations and excess work-in-progress (WIP). Pull systems like CONWIP limit WIP to prevent explosions. The document also discusses locating a push-pull interface and using techniques like Kanban to implement pull in a balanced way.

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HilalAldemir
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302 views32 pages

Source Book: Factory Physics (Hopp & Spearman, Source Book: Factory Physics (Hopp & Spearman, 2000)

This document contrasts push and pull production systems and discusses implementing pull systems in practice. It explains that push systems trigger work from outside the system based on forecasts, while pull systems trigger work from inside the system based on downstream demand. Push systems can lead to overloaded stations and excess work-in-progress (WIP). Pull systems like CONWIP limit WIP to prevent explosions. The document also discusses locating a push-pull interface and using techniques like Kanban to implement pull in a balanced way.

Uploaded by

HilalAldemir
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 32

Source book: Factory Physics (Hopp & Spearman,

2000)

Prepared by Dr. Sule Itir Satoglu

Purpose
 By Contrasting push and pull, explain the specific

characteristics of push and pull.


 Explain benefits of pull.
 How do we implement these in real world?
 Discuss difficulties of pull production control system.
 Discuss CONWIP production control system.

Prepared by Dr. Sule Itir Satoglu

What is pull?
Ohno said (1988):
 Workplaces can no longer base production on
desktop planning alone!
 Nowadays, customers stand in front of the
marketplace to speak, pull the goods they need, in the
amount and at the time they need them!

Prepared by Dr. Sule Itir Satoglu

Difference between Push and Pull?


 Mechanism that triggers the movement of the work!
 Push production control: Trigger comes from outside

of the system!
 Pull production control: Trigger comes from inside of
the system!

Prepared by Dr. Sule Itir Satoglu

Difference between Push and Pull?


Push production:
 System schedules (trigger from outside of the system)
release work orders based on demand forecast.
 Consecutive operations not consider status of the
following operation!
 Following operation slow (busy), but keep producing!

Prepared by Dr. Sule Itir Satoglu

Difference between Push and Pull?


Push production:
 Schedules/release time of work orders not modified
based on system status!
 Some stations overloaded: but still keep sending new

orders.

 But system is limited to bottleneck workstation.

Prepared by Dr. Sule Itir Satoglu

Difference between Push and Pull?


Push production control:
Flow is limited to the
bottleneck.
 So, why keep pushing?

Prepared by Dr. Sule Itir Satoglu

Difference between Push and Pull?


Pull production control:
 The job is released when a signal from the system is

received!
 Signal is based on the status of the process or other
downstream process!

 Signal: Completion of the work!

Prepared by Dr. Sule Itir Satoglu

Difference between Push and Pull?


Push Production:
Make-to-forecasted order
 Schedule that drives
system is based on demand
forecasts rather than actual
demand!
 MRP system is a push
system!

Pull Production:
Make-to-stock
 A predetermined level of
buffer stock tried to be
maintained!
 When stock level drops,
signal is released!

Prepared by Dr. Sule Itir Satoglu

Push Production Control

inventory

Prepared by Dr. Sule Itir Satoglu

10

Push Production Control through Suply Chain


(MIT opencourseware, 2004.)

Prepared by Dr. Sule Itir Satoglu

11

 MRP and MRP-II: push

based production
control
 MRP assumes that lead
times of the parts are
static.
 In fact, they are random
& vary based on system
loading (utilization
ratio).

Lead time

Problems of Push Production


(Li et al., 2007)
Control

Utilization (%)

In addition, lead times


vary based on their level of
variability! Sources of
variability?

Prepared by Dr. Sule Itir Satoglu

12

Problems of Push Production


Control
 MRP calculates lead time with a safety limit, and

makes back-scheduling.
 This causes early release of work orders , and this
increases manuf system workload & WIP.
 All these increase lead times and cause delays in
deliveries!
 MRP is a centralized prod planning system; far from its
users (manufacturers).
 This centralized planning decreases the lead time
responsibility of the shopfloor!
Prepared by Dr. Sule Itir Satoglu

13

Pull Production Control

Prepared by Dr. Sule Itir Satoglu

14

Pull Production Control through Supply Chain (MIT


opencourseware, 2004.)

Prepared by Dr. Sule Itir Satoglu

15

How about Real World Systems?


 Most of the real systems combine push and pull.
 Mechanical systems are not frictionless!
 Similarly, real systems face with unexpected events,

problems, variability.
 Ex: A job will be scheduled but held since line
congested: Hybrid push-pull system.

Prepared by Dr. Sule Itir Satoglu

16

Push-Pull Interface (Hopp&Spearman,


2000)
 Push-pull interface is decision of where to place pull

mechanisms,
 Divide system into push & pull segments!
 Locating the right position of the interface: important.
 Exploit advantages of both push and pull.

Prepared by Dr. Sule Itir Satoglu

17

Push-pull Interface (Hopp&Spearman, 2000)

Prepared by Dr. Sule Itir Satoglu

18

Push-pull Interface (Hopp&Spearmann, 2000)


 Interface can be located closer to the customer!
 Trade off between speed and flexibility!
 TacoUltimato: More flexible but slower!
 Quick Taco: Less flexible but responses more quickly!

Prepared by Dr. Sule Itir Satoglu

19

Push-pull Interface (Hopp&Spearman, 2000)


 Rush hours: Quick Taco is beneficial.
 Delivery by the end of the day: Taco Ultimato

preferred!

Prepared by Dr. Sule Itir Satoglu

20

Magic of Pull
The key reason of benefits of pull:
 Putting a limit on max amount of inventory in the
system
 In a Kanban system (pull), amount of inventory
limited to the number of containers and the Kanbans
attached!
 It prevents WIP explosion!

Prepared by Dr. Sule Itir Satoglu

21

WIP Explosion (Hopp&Spearman, 2000)


 If WIP is limited, WIP does not grow beyond

predetermined level, in case line stops/ slow down


(pull production).
 Lower costs.
 WIP not limited, and schedule by MRP is sent to
system (without cons. system conditions), piles of WIP
occur (push production)!!!!
 System is congested (overloaded)
 WIP Explosion!

Prepared by Dr. Sule Itir Satoglu

22

WIP Explosion
 In push production, over time, temporary workers,

altering due dates tried to achieve normal system


state!
 Corrective action not taken, before system is
overloaded!
 Higher manufacturing costs in push production!

 Because production speed is variable: over time etc.!


 More WIP & inventory costs!

Prepared by Dr. Sule Itir Satoglu

23

Reducing Variability
 Low lead time variability required for higher service

level to customer.
 Low lead time variab.: low std deviation of lead time

 Law (Lead Time): For a given routing,


 LT = f(Std dev. CT, mean CT)
 Based on Littles Law, WIP of a process is associated with
the cycle time of the process.
 If CT has high vaiability, then higher WIP.
 Therefore, we need to reduce variability of the CTs!

Prepared by Dr. Sule Itir Satoglu

24

Reducing Variability
 Lower lead times:Accurate due dates.
 Pull production achieves less variable lead time.
 As lead time increase, WIP increase (Littles Law).
 Pull production prevent WIP explosion, and lead time

explosion!

Prepared by Dr. Sule Itir Satoglu

25

CONWIP
 It means Constant Work-in Process.
 It is a hybrid push-pull prod control system
 For a production line, establish a limit on WIP in
the line and do not allow releases into the line as
long as WIP is at or above the WIP limit!
 WIP level is nearly constant!
 Only one set of system cards is used to manage
system WIP.
 No part is allowed to enter the system without a
card (authority).
Prepared by Dr. Sule Itir Satoglu

26

CONWIP
Push

Push

Pull

Prepared by Dr. Sule Itir Satoglu

27

CONWIP
 After a finished part is completed at the last

workstation, a card is transferred to the first


workstation and a new part is pushed into the
sequential process route.
 Production line consists of single routing, along which
all parts flow.
 Jobs are identical, so that WIP can be measured in
units (number of jobs or parts on the line).

Prepared by Dr. Sule Itir Satoglu

28

(Hopp & Spearman, 2000)

Full containers
Prepared by Dr. Sule Itir Satoglu

Authorization signals
29

CONWIP
 CONWIP systems are easier to implement and adjust,
 Single-card for authorization enough
 However, almost equal speed of processes needed!
 No supermarkets between the processes.

Prepared by Dr. Sule Itir Satoglu

30

Pull vs. CONWIP


 Kanban systems maintain tighter control of system

WIP through the individual cards at each workstation,


 Supermarket between each station needed!

Prepared by Dr. Sule Itir Satoglu

31

Kanban Game
 Now, we will play a Kanban game: Paper Airplane

Exercise!

Prepared by Dr. Sule Itir Satoglu

32

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