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Keep Calm and Stop the Line—Part 1

Christoph Roser — Tue, 02 Jan 2024 11:00:25 +0000

In industry, I often find the view that machines must run. The reasons given for this are that the machines were expensive investments, labor cost will accumulate, and the customer is waiting for products, hence the line must run. There is definitely some truth in this. However, the conclusion that the line must not stop ... Read more

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Real vs. Planned Data in Pull Systems

Christoph Roser — Tue, 30 May 2023 11:00:09 +0000

Pull systems like kanban and reorder point are a cornerstone of inventory management and fluctuation reduction in lean manufacturing. The production is managed based on ACTUAL consumption. Theoretically, it is also possible to include expected but not yet actual consumption. In this post, I will explain to you the concept behind it and why I ... Read more

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How Much to Adjust the Pull Inventory Limit

Christoph Roser — Tue, 29 Jun 2021 11:00:28 +0000

In my last post I looked at the behavior of the supermarket inventory for different kanban systems. In this post I will use this information to estimate how much the material availability of a system changes if you increase or decrease the inventory limit of your pull system (i.e., number of kanban). Parts of this ... Read more

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Behavior of a Kanban Supermarket

Christoph Roser — Tue, 22 Jun 2021 11:00:18 +0000

Setting up a kanban system is tricky, especially determining the number of kanban. The kanban formula is at best a rough estimate. It is usually advisable to adjust the number of kanban as the system is running. In general, if you have too much inventory, reduce the number of kanban. If you run out of ... Read more

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What Different Pull Systems Can Be Combined?

Christoph Roser — Tue, 08 Jun 2021 11:00:43 +0000

In my last few posts I have shown you different ways to establish pull systems, and which one is right for you. This post discusses how you can mix and combine these systems. You can combine some pull systems within the same pull loop, although there are some restrictions. Combinations of different kanban systems are ... Read more

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Which Pull System Is Right for You?

Christoph Roser — Tue, 01 Jun 2021 11:00:20 +0000

In my last few posts I showed you different types of pull systems, and an overview of the criteria on how to decide which one is right or you. In this post I finally give you a hands-on guide to decide which pull system to use. This blog post is loosely based on chapter 3.2 ... Read more

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What Are the Criteria to Decide on a Pull System?

Christoph Roser — Tue, 25 May 2021 11:00:59 +0000

There are different ways to establish a pull system. In my last post I gave an overview of the different types of pull system. Before telling you which one to use when I want to show you the different factors that should go into your decision. What do you have to pay attention to if ... Read more

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The Different Ways to Establish Pull Production

Christoph Roser — Tue, 18 May 2021 11:00:53 +0000

Kanban is the best known way to establish pull production. But it is not the only way. There are many different methods to create a pull system. This blog post is loosely based on my new book All About Pull Production: Designing, Implementing, and Maintaining Kanban, CONWIP, and other Pull Systems in Lean Production, which is ... Read more

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