1. Pull system APPROACH AT BOSCH SUPPLIERS M/PSD2-EU fatih cirkan 28. 03
Hello, My name is Fatih Cirkan and I welcome you to my presentation.
Today we will speak about Pull System.

2. Our Offer to Solve Your Daily Problems
Pull System Approach at RB Suppliers
Our Offer to Solve Your Daily Problems
High stocks
Volatile Markets
Daily Plan Changes
Stress in work
Special Transportation Costs
Unhappy Employees
Unhappy Customers
Bull-Whip
No Time to Improve
Express Shipments
Sorting actions
Long Reaction Times
Hunting for Parts Daily
Delivery Meetings with Customers
Supermarket?, Kanban?
What is Pull System?
Will it reduce my costs?
For which products?
Whom should I include in team?
How to Implement?
Will it reduce my stress?
Pull-System
Relation with lean tools?
Quick-change-over
Shopfloor Management
Why Pull-System?
Will it reduce my workload?
I will start with some key problems that we repeatedly heard from more than 100 suppliers.
You see 14 of them but it is easy to increase the numbers.
I want to ask you also if you have faced at least one of those problems in last months can you please raise your hand?
It is confirming also our experience and motivates me to make an offer to you?
Let me to go near my nice picture while speaking about my offer to you.
I offer you a method to do production control efficient way and to solve your problems.
Now you see some questions as well from our suppliers. 2
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3. Pull System Approach at RB Suppliers Agenda
Why Pull System?
What is Pull System?
How to Implement Pull System?
Today I will try to answer these questions basically why, what and how? 3
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4. Pull System Approach at RB Suppliers Agenda
Why Pull System?
What is Pull System?
How to Implement Pull System?
I will start with WHY Question because if the people don’t understand why, they will never be successful to implement pull. Or in other words they will never try. 4
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5. Why Pull-System? Bull-Whip Effect
Pull System at RB Suppliers
Why Pull-System? Bull-Whip Effect I
FIFO
OXOX
Everybody in this room knows that there is not an ideal customer who has everyday the same demand without any deviation.
We know it that we can’t control our costumer’s demands. But we can soften the effects of erratic orders in your production.
Pull controlled production flattens high demand peaks (“Bull-whips”) and leads you towards 100 % on-time delivery.
So calm down your production and gain more time for your Continuous Improvement Process. 5
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6. Why Pull System? What are the benefits to my company?
Pull System at RB Suppliers
Why Pull System? What are the benefits to my company?
ensure 100%
delivery fulfilment
eliminate special
transportation costs
calm down production
stop daily
plan changes
reduce
planning effort, more time for CIP
prevent
over production
Have transparency and standardized
procedures as basis for CIP*
Short Term
(0-1 month)
Implementation
After
Short/Mid Term
(0-6 months)
Optimization
Pull
Quick Changeover
Process Stabilization
(higher and stable OEE)
Reduction of Lead Time (inventories)
Shopfloormanagement
Reduction of lot size
Accelaration of reaction times (Service departments)
Increase the order accuracy of the customer
Leveling of customer withdrawal
Productivity Increase
(direct + indirect)
minimized
production costs
(OEE, productivity..)
indirect costs
inventory
costs
special transportation
Get ready, be competitive for the future!
pays back
Pull
Ready for
the future?
Pull system brings you in an advantageous position with numerous improvements.
Just after the implementation, you can sit back, cool and enjoy the calm breath of your supermarket.
Pull enables with decoupling 100% delivery fulfilment.
Kanban rule, no withdrawal prevents over production and moving only the good parts eliminates the sorting actions.
Your production calms down and you can focus to your core business and gain more time for your continuous improvement process.
My experience in 13 years showed that you need In 0-6 months period based on the value stream and the speed of the improvement process to optimize your system.
Just one simple target: Reduce Kanban loop inventories will lead you. Here are some focus points for optimization.
I want to mention that Shopfloor management is the heart of the improvement process
After concentration of the team and optimization of your system
Pull pays back to you after optimization with a long list of benefits.
In most of the cases the lead time and production control effort is reduced in average 50% express shipments are totally eliminated.
You are now more competitive and ready for the future
Better delivery and quality performance enable you to receive new customers to have a sustainable growth 6
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7. Why Pull System? HOW do you know the performance of the factory?
Supermarkets visually talk to you – Just observe them!
In 10 min shopfloor walk, you can have an idea of your actual performance
No more surprises within the day!
Immediate Action
Deviations
As planned
Give your team the target to reduce supermarket inventories
After pull implementation the inventory drivers (focus points) will be transparent
Re-directing the focus of the team helps them to find improvement potentials
How do you know the performance of your factory?
Do you have a transparency or do you need hours of meetings, excel sheets….
One more benefit I want to emphasize today is the clarity with the pull system
Supermarkets will be talking to the managers. You can have a 10 min Shopfloor walk to see what is going on in your production
With colours you have the feeling.
For me as a manager these Gemba walks and Shopfloor rounds was the best advantage (no more suprises within the day, saved my time.
The other advantage is,
If you only give the target to reduce supermarket inventories,
Your team will focus on the inventory drivers and come to you with the ideas and improvement potentials 7
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8. Pull System Approach at RB Suppliers Agenda
Why Pull System?
What is Pull System?
How to Implement Pull System?
Now lets have a look what is pull? 8
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9. Pull System at RB Suppliers What is Pull System?2
Return of Kanban to Kanban Post 4
Kanban-Chute 3
Return of Kanban to Process,
Lot-Size Building if Necessary
Customer
(e.g. subsequent
process)
Process 5
Post Production
Supermarket
Supplier 6
Product Delivery with Kanban in Supermarket 1
Customer withdrawal from Supermarket
Pull System is a production control method which is established as a closed loop controlled by the Customer withdrawal from a supermarket.
No customer withdrawal in other words no Kanban means no production.
Here we see an example. We have a process and installed supermarket, now we need a customer 
Aha he is here to withdraw his demand
This demand will trigger the post production (Without Kanban no production)
Now we will see how the Kanban is having his loop.
Our loop is completed with the last step. The time we need from customer withdrawal to delivery in supermarket is called the replenishment lead time and determines how fast we can react to customer order. 9
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10. What is Pull System? Possible Elements
Pull System at RB Suppliers
What is Pull System? Possible Elements
Lot Size Collector
Kanban Chute
Supermarket
Some example photos from a possible system.
On the right side you see a supermarket which decouples the process from its customer
When the customer withdrawal takes place than Kanban is free and collected in a box.
Kanban is then transferred to the lot formation box and will wait there until the lot size is reached
Once the lot size is reached it is transferred to the machine or line based on the FIFO principle and the lot is produced
My key message here is, the elements of the pull system are easy to install and you don’t need to have high invest to start.
In Blaichach plant you will see a more mature system also combined with Industry 4.0.
Important is it can be improved step by step. 10
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11. Pull System Approach at RB Suppliers Agenda
Why Pull System?
What is Pull System?
How to Implement Pull System?
We know now why and what pull is and motivated to implement Pull.
How to do it? 11
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12. How to implement Pull System? The Implementation Wheel
Pull System at RB Suppliers
How to implement Pull System? The Implementation Wheel
5-Capacity Calculation
2-Planning Period
3-Range of Part Numbers
6-Production
Lot Size
4-Customer Order Behaviour
1-Definition Control Loop
7-Design of Control Loop
8-Go-Live preparation
P0 P1 P2
3 pcs
Here I have a stepwise approach for you. We call it implementation wheel.
We created it and named it as a wheel thinking that our suppliers don’t have to invite the wheel again 
Before the implementation motivate your team with the upcoming benefits
Let them to test it hands on, a pull simulation is always helpful for AHA effects
With a motivated team you can start to implement step by step.
Decide the value stream, machine, parts, frequencies.
Than calculate your Kanban loops. Result will be a Kanban calculation which is ready to be implemented.
Then you are ready to go. 12
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13. How to implement Pull System? Best Practice for Implementation
Pull System at RB Suppliers
How to implement Pull System? Best Practice for Implementation
Management Support and Attention
Use shopfloor management to drive CIP
Daily
15 Min
Shopfloor
Involvement of relevant functions
Involve, train, support, motivate and coach your people
Pull together, pull stronger!
Eliminate the deviations together
Go to Gemba
Management support and involvement of all related functions are key factors for success.
especially key players like logistics, production, IT and maintenance.
Industry 4.0, connecting the machines, making Kanban calculations in the ERP system, Supermarket Visualization and KPI checks, updating the process parameters…
USE THE POWER OF COMMUNICATION AND TRANSPARENCY.
You can only change the minds if you hear your people, consider their ideas, let them be part of your strategy
Pull is a minset change, As Einstein says: We cannot solve our problems with the same thinking we used when we created them.
Pull is a mindset change! 13
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14. Start with Pull now! Don´t Wait anymore!
Today you have seen an easy method which helps you to be one step beyond your competitors.
Now you are in charge.
Start with Pull now! Don´t Wait anymore!
You will receive a flyer which summarizes the key points from my presentation.
If you need PSD support for pull system please get in touch with your buyer.
Your questions are now welcome  14
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15. Thank you