A pull production system operates based on actual customer demand. Production is triggered by customer orders or consumption, ensuring that products are manufactured just in time to meet market needs. This method minimizes excess inventory and reduces the risk of overproduction3. Let’s explore the essential features of a pull production system in more detail:

Supermarket Pull System: This is the most basic type of pull system. Each process has a store (often called a supermarket) that holds an amount of each product it produces. As material is withdrawn from the supermarket by the downstream customer process, a kanban or other information is sent upstream to authorize the upstream process to replace what was withdrawn. Each process is responsible for replenishing its supermarket, making daily management relatively simple. However, carrying inventory for all part numbers produced may not be feasible if the number of part numbers is large2.

Sequential Pull System: Also known as a “b-type” pull system, this approach is used when there are too many part numbers to hold inventory of each in a supermarket. Products are essentially “made-to-order,” minimizing overall system inventory. In a sequential system, the scheduling department sets the right mix and quantity of products to be produced. Each following process produces in sequence the items delivered by the preceding upstream process. FIFO (first in, first out) of individual products must be maintained throughout. This system creates pressure to maintain short and predictable lead times2.

In summary, a pull production system ensures that work starts only upon customer request, reducing waste and promoting efficient resource utilization. It aligns with the principles of Just-in-Time (JIT) production and emphasizes producing goods to meet actual demand13.

 1: Pull System: Definition, Its 3 Types & Differences with Push 2: Pull Production - Lean Enterprise Institute 3: Navigating the Manufacturing Landscape: Pull System vs. Push System in Production Planning