Material Flow & Pull Systems

If material isn't where it needs to be, flow doesn't exist. Many shops attempt to implement pull systems, but end up with: Kanban cards no one follows Supermarkets that become uncontrolled storage Material handlers constantly reacting to "emergencies" Operators leaving their stations to hunt for parts The problem isn't the tools. The problem is that material flow was never designed as a system. In Material Flow & Pull Systems, Nick Arkesteyn provides a practical, field-tested guide to designing pull systems that actually work in high-mix, low-volume (HMLV) environments. This book focuses on how material moves, signals, and supports production flow—not theory, not software, and not abstract Lean diagrams. Inside this Deep Dive, you'll learn how to: • Design supermarkets that buffer variation without hiding problems • Create Kanban systems that trigger replenishment instead of confusion • Build water strider routes that stabilize flow and reduce interruptions • Separate production problems from material handling problems • Prevent pull systems from collapsing under real-world pressure • Implement pull incrementally without disrupting operations Each concept is presented as a complete, executable improvement project—not a conceptual overview. One time through this book = one completed improvement project This is Volume 5 of the Lean Line Pro Deep Dive Series, which focuses on building practical Lean systems for high-mix manufacturing. Volumes 1–4 establish product families, reduce changeover time, design flexible cells, and create effective schedules. This volume ensures material flow supports those systems instead of undermining them. Who this book is for: Manufacturing Engineers Continuous Improvement Professionals Operations Managers Lean Practitioners working in high-mix environments If your shop struggles with material shortages, excess WIP, or constant expediting, this book shows how to design pull systems that work in the real world.