Learn six steps to identify customer demand for a pull system, a lean approach to manage work and materials. Reduce waste, improve quality, and increase satisfaction.

While establishing your pull limits, make sure that you conduct a thorough examination of your systems in place. As they say, you need to come out of your comfort zone to expand your comfort zone, and there is always room for improvement and more efficiency. Hence, you need to push yourself while setting your pull limits. It is essential for your growth.

Deixe exposto visualmente seu nível de estoque de produtos acabados, WIP e MP, de maneira que seus fornecedores possam evitar o efeito chicote.

Last updated on Sep 16, 2024

How do you identify customer demand for a pull system?

A pull system is a lean approach to managing the flow of work and materials based on customer demand. Unlike a push system, where work is planned and scheduled in advance, a pull system responds to the actual needs and preferences of the customers. This way, you can avoid overproduction, inventory waste, and customer dissatisfaction. But how do you identify customer demand for a pull system? Here are some steps to help you:

1 Understand your value stream

The value stream is the sequence of activities that deliver value to your customers. It includes the processes, people, resources, and information involved in creating and delivering your products or services. To understand your value stream, you need to map it out and identify the value-added and non-value-added steps. This will help you see where the waste and inefficiencies are, and where you can improve the flow and quality of your work.

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Chris Wigginton, MBA

Experienced Continuous Improvement Consultant | Servant Leader | Data-Driven Problem Solver | MBA, MPH | Skilled in Program Development, Project Management, Process Improvement and Coaching
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Understanding your value stream is crucial for identifying inefficiencies and areas for improvement. By mapping out each step, you can distinguish between value-added and non-value-added activities, which is essential for streamlining processes and driving efficiency. This data-driven approach allows you to pinpoint waste and optimize the flow of work, ultimately enhancing the quality and delivery of your products or services.

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Nilson Rodrigues da Silva

Gerente de projetos no Lean Institute Brasil | Neurociências e Lean Six Sigma
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O mapeamento de fluxo de valor é muito importante para sairmos das melhorias pontuais passando a enxergar o fluxo para atuar em melhoria sistêmica.

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Travette Webster, Ed.D., MBA

Chief Operating Officer
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When identifying and mapping your value stream, identify the first step and the last step first. Then define what happens in between. By mapping the bookends first, it ensures you stay within the scope of the value stream. Remember "value" is in the eyes of the customer, not you as the employee. With each step ask "would the customer pay for this step to happen?" If the answer is no, then 9/10 the step is non-value adding.

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2 Define your pull triggers

A pull trigger is a signal that indicates when a customer needs or wants something from you. It can be an order, a request, a feedback, or a problem. You need to define your pull triggers for each stage of your value stream, and make them visible and accessible to your team. For example, you can use kanban boards, cards, bins, or electronic systems to track and communicate your pull triggers. This will help you align your work with customer demand and avoid overloading your system.

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Alexander Jones MCMI ChMC MBA

Seasoned Operational Excellence Leader & Founder | Chartered Management Consultant | Certified Lean Six Sigma Black Belt | Executive MBA | Transforming Businesses through Lean Processes & Innovation
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These are a few approaches to get started with that will provide data and insight into the solution required. Understand customer needs and wants. Conduct market research, customer surveys, and focus groups to gather information on customer needs, preferences, and buying habits. Analyse historical sales data to identify patterns in customer demand. Products in high demand, at what times of the year, and in which regions etc. Monitor inventory levels to determine which products are running low, this can help you identify which products are in high demand. Use forecasting such as trend, regression, and time series analysis to predict future customer demand. This helps you plan production and inventory levels to meet customer needs.

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Nilson Rodrigues da Silva

Gerente de projetos no Lean Institute Brasil | Neurociências e Lean Six Sigma
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O sistema puxado nos aproxima da demanda real, não fazer de acordo com sua própria capacidade, mas de acordo com a demanda dos clientes.

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3 Establish your pull limits

A pull limit is a constraint that limits the amount of work or materials that can enter or exit a stage of your value stream. It helps you balance the supply and demand of your system and prevent bottlenecks and backlogs. You need to establish your pull limits based on the capacity and variability of your processes, and the expectations and requirements of your customers. For example, you can use work-in-progress (WIP) limits, batch sizes, lead times, or service levels to set your pull limits.

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Ajay Gupta

Co-Founder of Rishihood University | Founder of the Bachpan and AHPS Group of Schools | Host of "Saksham Yatra", a Talk Show | Storyteller
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While establishing your pull limits, make sure that you conduct a thorough examination of your systems in place. As they say, you need to come out of your comfort zone to expand your comfort zone, and there is always room for improvement and more efficiency. Hence, you need to push yourself while setting your pull limits. It is essential for your growth.

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Nilson Rodrigues da Silva

Gerente de projetos no Lean Institute Brasil | Neurociências e Lean Six Sigma
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Quando estamos criando o sistema puxado, em alguns pontos precisamos criar supermercados, esses devem ser muito bem calculados, normalmente em 3 partes, 1a - Demanda diaria x dias para reposição 2a - Estudar e aplicar estoque que represente a variação de demanda 3a - Calcular as ineficiências do processo produtivo e aplicar esse percentual no calculo do estoque como sempre digo, cada empresa tem o estoque que merece.

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4 Monitor and adjust your pull system

A pull system is not a static or rigid system. It requires constant monitoring and adjustment to respond to changes in customer demand and market conditions. You need to measure and analyze your pull system performance using key indicators such as cycle time, throughput, quality, and customer satisfaction. You also need to collect and act on customer feedback and suggestions to improve your value proposition and delivery. You can use tools such as PDCA (plan-do-check-act) cycles, kaizen events, or A3 reports to facilitate continuous improvement.

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Nilson Rodrigues da Silva

Gerente de projetos no Lean Institute Brasil | Neurociências e Lean Six Sigma
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O sistema puxado é vivo, portanto ficar de olhos nas mudanças de demanda, variação e mudanças de peformance no processo produtivo devem estar representados no calculo do estoque atual. Reduzir o supermercado é o merito de quem trabalha em flexibilidade, redução de lotes, aumento de eficiência produtiva e de logística e agilidade.

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5 Train and empower your team

A pull system is not only a technical or operational system. It is also a cultural and behavioral system that requires the involvement and empowerment of your team. You need to train and educate your team on the principles and practices of lean thinking and pull system. You also need to encourage and enable your team to make decisions, solve problems, and implement improvements based on customer demand and value. You can use methods such as gemba walks, huddles, or coaching to support and motivate your team.

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Nilson Rodrigues da Silva

Gerente de projetos no Lean Institute Brasil | Neurociências e Lean Six Sigma
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As pessoas a volta do process precisam entender como funciona o conceito de supermercado para atender a demanda e quais são os sistemas de movimentação, kanban manual, kanban eletronico, caixa kanban, seja ele qual for, que seja padronizado e respeitado por todos.

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6 Collaborate with your suppliers and partners

A pull system is not an isolated or independent system. It is part of a larger network of suppliers and partners that contribute to your value stream. You need to collaborate and communicate with your suppliers and partners to align your pull system with their capabilities and expectations. You also need to share and exchange information, feedback, and best practices to optimize your supply chain and delivery. You can use techniques such as supplier development, vendor-managed inventory, or joint planning to build trust and synergy with your suppliers and partners.

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Daniel Madazio Rahal Farhat

Manager | Consultant | Mentor | Continuous Improvement | Lean | Agile | Operational Excellence | Six Sigma | Change Management
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Deixe exposto visualmente seu nível de estoque de produtos acabados, WIP e MP, de maneira que seus fornecedores possam evitar o efeito chicote.

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7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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Omar Brito

TPS Learner and practitioner by 25 years.
(edited)
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En un sistema Jalar el nivel de la demanda y su comportamiento los estudias y la entiendes antes de elaborar el sistema en si. Es indispensable que definas el tipo de conexión que puedes diseñar (SM=supermercado): SM de MP, SM de WIP, SM de PT o secuenciado. Con esto definido es importante que hagas los cálculos para los niveles de inventario y las secuencias tanto de producción como de entrega. Si los niveles son correctos: 1.-Mantienen el flujo y 2.-Tienden a mantenerse entre el nivel máximo y cero, entonces podrás comprobar que la forma en que estudiaste y entendiste la demanda fue la adecuada. Saludos...

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How do you identify customer demand for a pull system?

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1 Understand your value stream

2 Define your pull triggers

3 Establish your pull limits

4 Monitor and adjust your pull system

5 Train and empower your team

6 Collaborate with your suppliers and partners

7 Here’s what else to consider

Lean Thinking

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