Pull Systems
Did you know that 90% of US factories still build to forecast and do not use a push system?

Also, worse yet, 95% of factories installing lean manufacturing systems still are retaining push
systems! It’s like having a hamburger without the beef! Unbelievable! Huge savings and
customer service is lost.

What is a pull system?

A pull system builds products that reflect customer needs. You build to actual orders or a
combination that includes strategic finished goods for key customers using kanbans for
immediate shipment.

We have specially-designed kanban systems.

Our combination pull system and kanbans dictates what the factory builds.

Savings?
1. Customer delivery is at least 99.5% as requested
2. Reduces in-process and finish goods inventory by 30-50% in dollars
3. Reduces lead times to customers a minimum of 50 – 75%
4. Reduces factory space by 30-50%
5. Eliminates 50-80% of all handling costs

WCC’s POWERFUL PULL SYSTEM REVIEW
Plus, if you marry this pull system into a strategic plan for implementing total lean manufacturing
for your factory, you can reduce over all cost 40 – 60%. How many sales dollars would you have
to generate to make this kind of savings?

We can do this together as a team.

How confident are we?

If you and your team agree to a detailed game plan for implementation and we agree on the
starting matrix of measurements, we guarantee a 200% return on all of our costs. (This includes
a pull system and lean manufacturing implementation.)

Yes, but what if we fail to do so?

Again, once the game plan is agreed on by all of us, the auditor of the plan will be your
CFO. If we fail, and say only achieve 170% savings, we’ll work with your CFO and agree
on the dollars missed to save 200% and we will issue a check – cash for the difference.
We don’t know of any other consultant who would dare make you this offer.
ACTION
BENEFITS
1. Reduce lead times by a minimum of 60%
 Powerful marketing and sales tool
2. Reduce floor space by 50%
 In-house room for new products or
warehousing
3. Reduction of in process inventory by 50%
 Less handling and storage needed
4. Increase inventory turns by 100%
 Increasing velocity in manufacturing saves
cash flow and borrowing of money
5. Implement WCC’s unique Kanban system
(secret)
 Eliminate the need for MRP in scheduling; use
MRP only for business planning
6. Eliminate surprise shortages
 Average factories today lose 10% of their
capacity. Labor costs increase by 5% when
waiting for needed materials.
7. Simplify software needs and systems
 Eliminate 80% of computer software and
electronic scheduling using visual factory
techniques. The employees will be able to
control scheduling and production needs
8. At least 25% less handling and storage of
inventory
 Freeze hourly headcount replacements. Let
attrition reduce the workforce or use the extra
people for a new product you can acquire.
Huge savings and better costs.
For further reading, click on WCC’s Pull Systems White Paper