In today’s competitive business environment, organizations continuously seek methods to optimize their operations and eliminate waste. Two fundamental approaches to managing workflow and production have emerged as critical considerations: pull systems and push systems. Understanding the differences between these methodologies and knowing when to implement each can dramatically impact your organization’s efficiency, customer satisfaction, and bottom line.
This comprehensive guide explores both systems, their applications within lean six sigma frameworks, and how to successfully implement flow in your processes to achieve operational excellence. You might also enjoy reading about Setup Time Reduction Techniques: SMED and Quick Changeover Methods for Enhanced Manufacturing Efficiency.
Understanding Push Systems: The Traditional Approach
Push systems represent the conventional method of production and workflow management that many organizations have relied upon for decades. In a push system, work moves forward based on schedules, forecasts, and predetermined production plans rather than actual customer demand. You might also enjoy reading about Pilot Testing in Six Sigma: How to Test Solutions Before Full Implementation.
How Push Systems Operate
In a push environment, production begins at the first stage of the process and continues through each subsequent stage until completion. Materials and work items are “pushed” through the system according to a master schedule, regardless of whether the next stage is ready to receive them or whether there is immediate demand for the finished product. You might also enjoy reading about Visual Management in Improve Phase: Making Process Performance Visible for Lasting Results.
Organizations using push systems typically rely on forecasting models to predict customer demand and then create production schedules accordingly. Each department or workstation produces at maximum capacity or according to schedule, pushing their output to the next stage in the process.
Advantages of Push Systems
- Predictable scheduling: Push systems allow for detailed advance planning and resource allocation
- Economies of scale: Large batch production can reduce per-unit costs
- Continuous operation: Workstations maintain steady production rates
- Buffer against uncertainty: Inventory stockpiles can protect against supply chain disruptions
Disadvantages of Push Systems
- Excess inventory: Overproduction leads to storage costs and capital tied up in unsold goods
- Waste generation: Products may become obsolete before being sold
- Quality issues: Defects may not be discovered until large batches are already produced
- Reduced flexibility: Difficulty adapting to changing customer demands
- Longer lead times: Products spend more time waiting in queues between processes
Understanding Pull Systems: The Lean Approach
Pull systems represent a paradigm shift in how organizations approach production and workflow. Rooted in lean manufacturing principles pioneered by Toyota, pull systems prioritize actual customer demand over forecasted predictions.
How Pull Systems Operate
In a pull system, production is triggered by actual consumption or customer orders. Nothing is produced until there is a signal that it is needed. Work moves through the system only when the downstream process is ready to receive it, creating a natural rhythm that prevents overproduction and reduces waste.
The most common visual management tool used in pull systems is the kanban card, which signals when inventory needs to be replenished or when the next work item should begin. This creates a smooth, continuous flow where each stage only produces what the next stage requires.
Advantages of Pull Systems
- Reduced inventory costs: Organizations maintain only necessary stock levels
- Improved quality: Problems are identified and addressed immediately
- Greater flexibility: Systems can quickly adapt to changing customer demands
- Shorter lead times: Less waiting time between process stages
- Reduced waste: Minimizes overproduction, excess inventory, and obsolescence
- Better cash flow: Less capital tied up in work-in-progress inventory
Disadvantages of Pull Systems
- Vulnerability to disruptions: Limited inventory buffers mean supply chain issues have immediate impact
- Initial implementation challenges: Requires cultural change and process redesign
- Demand variability: Highly unpredictable demand can strain the system
- Supplier dependency: Requires reliable suppliers who can respond quickly
Implementing Flow Using Lean Six Sigma Methodology
The integration of pull systems within a lean six sigma framework provides a structured approach to implementing flow in your processes. The methodology combines lean principles focused on waste elimination with Six Sigma’s data-driven problem-solving techniques.
The Recognize Phase: Your Starting Point
Before implementing any changes to your workflow system, you must first recognize phase opportunities for improvement. This initial step involves acknowledging that problems exist and identifying where your current system falls short of optimal performance.
During the recognize phase, organizations should conduct thorough assessments of their current state, including mapping existing processes, identifying bottlenecks, measuring cycle times, and documenting waste in all its forms. This phase establishes the baseline against which future improvements will be measured.
Key Steps for Implementation
1. Value Stream Mapping
Create detailed maps of your current processes to visualize material and information flow. Identify value-added and non-value-added activities, highlighting areas where work accumulates or waits unnecessarily.
2. Identify and Eliminate Bottlenecks
Bottlenecks constrain your entire system’s throughput. Use data analysis to identify constraint points and implement targeted improvements to balance workload across all stages.
3. Establish Takt Time
Calculate the rate at which products must be completed to meet customer demand. Takt time becomes the drumbeat that synchronizes your entire production system.
4. Implement Visual Management
Create visual signals such as kanban cards, color-coded bins, or electronic dashboards that communicate status and trigger action throughout your system.
5. Standardize Work Processes
Document best practices and create standard operating procedures that ensure consistency while allowing for continuous improvement.
6. Train Your Team
Successful implementation requires buy-in and understanding from everyone involved. Invest in comprehensive training that explains the why behind the changes, not just the how.
Hybrid Approaches: Finding the Right Balance
Many successful organizations recognize that pure pull or push systems may not suit every situation. Hybrid approaches that incorporate elements of both can provide optimal results.
For example, a manufacturer might use push systems for long-lead-time raw materials that must be ordered in advance, while implementing pull systems for final assembly based on actual customer orders. This strategy balances the predictability of push with the responsiveness of pull.
When to Use Each System
Push systems work best when:
- Demand is stable and predictable
- Production lead times are long
- Products have extended shelf lives
- Economies of scale are significant
Pull systems work best when:
- Demand is variable or unpredictable
- Products have short lifecycles or can become obsolete
- Customization is important
- Storage costs are high
- Quality and flexibility are priorities
Measuring Success and Continuous Improvement
Implementing flow through either pull or push systems is not a one-time project but an ongoing journey. Establish key performance indicators to monitor system effectiveness, including cycle time, inventory turnover, on-time delivery rates, quality metrics, and customer satisfaction scores.
Regular review sessions should examine these metrics, identify new improvement opportunities, and make incremental adjustments. This continuous improvement mindset ensures your system evolves with changing business conditions and customer requirements.
Conclusion
The choice between pull and push systems, or a hybrid combination of both, depends on your specific business context, customer requirements, and operational constraints. While pull systems aligned with lean six sigma principles offer significant advantages in waste reduction and flexibility, push systems may still serve important functions in certain situations.
Success lies not in dogmatically adhering to one approach but in thoughtfully analyzing your unique situation during the recognize phase and implementing the flow methodology that best serves your customers and organization. By understanding the strengths and limitations of each system, you can design workflows that maximize value delivery while minimizing waste, positioning your organization for sustained competitive advantage.
