This is how to make materials flow (EN)

"From beautifully designed pull system to working reality"

Pull on paper is one thing. Pull that actually works in your production environment is something else. This practical workbook shows you how to achieve material flows that really work.

What this book solves

You have designed a pull system. Flow cells have been set up. Kanban cards are hanging on the board. But in practice, things are not running smoothly: materials arrive late, stocks are running high, routes are inefficient, and no one knows exactly who needs to replenish what and when.

Making Materials Flow is not about designing pull, but about making it work. The practical techniques, the logistical details, the daily operation.

What you learn

Systematic approach to material management

• Plan For Every Part (PFEP): managing all aspects of material management
• 6 practical rules for kanban that actually work
• Standardization of material delivery routes

Optimizing internal logistics

• 2 types of material delivery routes: linked and unlinked
• Impact on occupancy and inventory levels by type
• 2 types of provisioning and when to use which one

From theory to practice

Using a comprehensive practical case study, you will see step-by-step how to build a working system. Richly illustrated with diagrams, overviews, and concrete examples.

Why this book is important

The apparent simplicity of material handling is deceptive. It is often thought that pull only works for predictable, simple assembly with a limited number of parts. 

Toyota proves the opposite. Even in complex environments with thousands of parts, this system works, provided you apply the right techniques. This workbook shows you exactly how.

How this book fits into your Lean journey

Can be used independently:
This book stands alone as a practical guide to material handling.

Optimal combination:

1. *How to create a leveled pull system* → design your pull system
2. *How to get your materials flowing* → make that design work in practice
3. *How to create continuous flow* → optimize flow within work cells

Each book has its own value, but together they form a complete picture.

Who is this book for?

Ideal for:
- Production planners who want to make pull work
- Operations managers facing logistical challenges
- Industrial engineers who design material flows
- Lean practitioners who move from design to implementation
- Logistics coordinators in production environments

Situations in which this book can assist:
- "Our pull system is not functioning as intended"
- "Materials are arriving late or in excess"
- "Our internal logistics are inefficient"
- "We want to transition from push to pull, but are uncertain how to implement this operationally"

Level: For professionals with basic knowledge of Lean who want to implement pull operations.

💡 Common reaction:
"Finally, a book that doesn't stop at design, but shows you how to make it really work."

Additional Information