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Stockless production

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Stockless production
Stockless Production
From Push to Pull

Their idea behind the change was:

• At HP there was in 1983 a division which wanted to make a change over from Push to Pull.
• It was the Greely Colorada Division
• They made Disc Units
• Their goal was to get a batch quantity of one piece

Out of balance Scrap

1

Unreliable deliveries 2

The Film Stockless Production

What did they try to realize at HP:
• Advantages:
⇓ Inventory
⇓ Lead time
⇓ Space
⇓ Work on hand
⇓ Rework

Be a were of the problems in this simulated production line.
Don’t look only to the working procedures. Watch to the people themselves.
Write down all what you find remarkable. • Effects:
⇑ Quality
⇑ Productivity
⇑ Involvement
3

Performance-Indicators 1

Produce and Package the Box
Halve a box
Box with sticker
Box with wire stich
Sticker on box

To sticker

To Stitch

Tape it

4

Method Push
Measurement 6 pieces
Space

Pull
3 pieces

Pull
1 piece

Work on Hand
Cycle time
Lead time
Rework

To Pack

Quality
Problems

Box in the Box

5

6

© CoLogic/ Hessel Visser hesselvisser@chello.nl 1

Performance-Indicators 2
Method Push
Measurement 6 pieces
Space
2 tables

Pull
3 pieces

Performance-Indicators 3

Pull
1 piece

Method Push
Measurement 6 pieces
Space
2 tables

Pull
3 pieces
2 tables

Pull
1 piece
1 tables

Work on Hand

30 pieces

Work on Hand

30 pieces

12 pieces 4 pieces

Cycle time
Lead-time
Rework

3:17 minute Cycle time
Lead-time
Rework

3:17 minute 1:40 minute Quality
Problems

Hidden

Quality
Problems

Hidden

26 pieces

26 pieces

0:19 minute 10 pieces 3 pieces
Visible

7

The “fixed-position stop system”

Results at HP
Subject
Inventory
Space

Before
2,8 months
4000 m2

After
1,2 months
2000m2

Work on Hand 5 days

2,5 days

Productivity

115%

100%

8

9

10

ANDONS

11

12

©
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