Integrated Lean Flexibility

Traditional push methods include MRP, re-order points, and optimum order quantities. Modern pull manufacturing methods include utilization of kanban, backflushing component inventory, backto-back orders for single piece flow, etc. The flexibility present in Integrated Lean (push/pull flexibility) combines methodologies and allows concurrent use of traditional and modern techniques.

The key to Integrated Lean manufacturing is providing kanban signals throughout the supply chain by utilizing the Internet to communicate instantly from the shop floor. Upon product consumption, the ERP system communicates material requirements directly with the vendor. Integrated Lean extends the boundaries of the production floor to coordinate inventory for synchronized single piece flow through the supply chain.

Current manufacturing practices have been made cumbersome by the imposition of data recording activities required by manufacturing systems through the release, issuing, and expediting of the infamous work order. An Integrated Lean system utilizes full containers to signal the completion of product and backflushes the component material within the ERP system. Additionally, the Integrated Lean system (pull) can work simultaneously and in harmony with your MRP planning (push) to schedule your shop floor bottlenecks so that the bottleneck becomes the heartbeat (pull) for the remainder of the plant. Although originally scheduled, the bottleneck may use the Integrated Lean backflush routines as well!

An ERP system integrated with lean manufacturing techniques provides a management toolset which allows the end users to achieve profitability for the company by being flexible enough to support both traditional and modern manufacturing methods.

Download the full length White Paper entitled Integrated Lean – Giving ERP the Flexibility to Push and Pull