How to create a levelled pull system

Practical workbook that explains levelling and pull on the basis of a fictitious case. The case is realistic: many complications, exceptions and special situations are discussed.

Leveling and pull are among the best known elements within Lean. Value Stream Mapping leads you to determine where continuous flow is not possible and where pull is needed. Michael Ballé and Dan Jones write on Planet Lean: "[You] need to fully master the mechanics of a pull system in its various forms [...] Pull is a technique specific to lean that creates the conditions for learning". In short, there are plenty of reasons to find out more about levelling and pull, which is why these subjects deserve their own workbook.

Step by step author Art Smalley (former employee of Toyota in Japan) explains in this book how to create level pull. You learn by means of a practical case:

• two types of levelling (i.e. of the volume and of the mix)
• three types of pull (complementary pull, sequential pull and mixed pull), and how to choose
• three forms of pull in batch processes and many forms of pull in flexible processes
• three types of stock, and determining their required size
• the role of 5S
• four main types of kanban, and when to use which one

This is perhaps the most difficult workbook in the series. The reward is also great: a working leveled pull system feels almost like magic. Meanwhile, you begin to get a good idea of the probably unexpected breadth and depth of Lean.

The title of this book was also chosen deliberately. It's not called "How to implement a leveled pull system" but "How to create a leveled pull system". In fact, equalised pull can never be implemented - there are always many real causes and valid reasons why it can't be done in a particular situation. So this workbook doesn't teach you how to implement zero-level pull; it teaches you how to see and understand what needs to change in your situation so that it is possible.

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