Pullsysteme

pullSysteme is a term used to describe a family of production and inventory-control methods in which actual demand from downstream processes or customers triggers production and replenishment upstream. In contrast to push systems, which rely on forecasts and planned schedules, pull systems start with real consumption signals to determine what to produce or restock next.

Common implementations include Kanban-based signaling, two-bin systems, or supermarket-style replenishment. Signaling mechanisms may be physical cards, containers, electronic signals, or software-based alerts. The core idea is to limit work in progress and produce in small, controlled batches that align closely with current demand, thereby reducing waste and lead times.

Key principles involve aligning production to takt time (the rate of customer demand), maintaining smooth flow, and employing visual or digital signals to trigger replenishment. Heijunka (leveling) and just-in-time thinking support steady throughput and responsiveness to changes in demand.

Applications span manufacturing and logistics, such as assembly lines, distribution centers, and supplier networks. The pull concept is also observed in some software development and service delivery practices, where work items are pulled into progress by demand signals rather than pushed by a forecast.

Benefits of pullSysteme include lower inventories, reduced waste, shorter lead times, and improved adaptability to actual demand. Limitations arise when demand is highly volatile, supply reliability is weak, or signaling and data quality are poor. The approach requires reliable communication, cooperative suppliers, and disciplined change management to maintain flow and avoid stockouts.