Creating a Lean Six Sigma Pull System
Lean Six Sigma is a leadership methodology that significantly improves process Quality, Speed,Costs, and Agility. Practitioners leverage many tools and methods to transform a current stateprocess into a stabilized
future state. One of the concepts applied is called a “Pull System” andit is very different than the “Push System” models that we are often changing from. This articlewill show you how to design a “Pull System” for your process.
The following definitions will be used to describe the speed, efficiency, throughput (Exit Rate),and capacity of a process:
Process Cycle Time (PCT):
The time from release of a product into a process until itscompletion. Also called Process Lead Time (PLT)
The elapsed time from when a new mobile phone customer calls, to when the NewMobile Account is Setup, averages 14 days.
Product, Service, or Transaction that is within the process boundaries.It is the unit moving through the process. As the WIP moves through the process, it will changein Fit, Form, or Function, as it is transformed into the final output that the customer receives.
There were 3000 refinance applications in process at months end
Exit Rate (Throughput):
The process output over a defined period of time
Process closed 100 new mobile accounts per day last month
Why Use a Pull System?
Pull Systems limit the amount of
“Stuff in Process” in order to control
the process cycletime.
Pull Systems help to stabilize processes to make it easier to apply analysis &improvement tools.
To control and reduce the amount of product/information in process, allowing a sharperfocus on problem areas, with
less “stuff” to get
in the way of analysis efforts.
To control and reduce cycle time to generate faster feedback cycles on improvementprojects, which also increases the process speed and thus cycles of learning.
The primary goals of a work control system are to stabilize then reduce process cycletime and cycle time variability.
Pull Systems are Agile, Faster, and Predictable