Tennessee MEP · Lean Manufacturing
Stop producing based on forecasts and start producing based on demand. Kanban pull systems replace push-based scheduling with visual signals that control flow, reduce overproduction, and cut inventory across your entire value stream.
On-site consultants across Tennessee — Nashville, Memphis, Knoxville, Chattanooga, Jackson, Tri-Cities. No commitment required.
Most manufacturers run push systems without realizing the cost. Here is what the shift looks like.
Push system
✕ Production runs based on forecast
✕ Inventory builds between processes
✕ Overproduction hides problems
✕ Lead times are long and unpredictable
✕ Scheduling is complex and constant
Pull system
✓ Production triggered by actual demand
✓ WIP is capped at every process step
✓ Problems surface immediately
✓ Lead times are shorter and consistent
✓ Visual signals replace complex scheduling
A Kanban system uses simple visual signals — cards, bins, empty squares, or electronic signals — to control production and material movement. The concept is straightforward.
01
Customer uses material
The downstream process consumes parts from a container or designated location.
02
Signal is sent
When the container is empty or hits a reorder point, a Kanban signal goes to the upstream process.
03
Upstream produces
The supplier process produces only the quantity specified on the Kanban signal. Nothing more.
04
Material flows back
Replenished material moves to the downstream process. The loop repeats. Inventory never exceeds the Kanban quantity.
The key rule: No Kanban signal, no production. This single discipline prevents overproduction — the most damaging of the seven wastes in lean manufacturing.
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Tennessee MEP consultants work on-site inside your facility to analyze your current material flow, calculate Kanban quantities, design the signal system, train your team, and support implementation. Engagements are tailored to your production environment whether you run high-mix low-volume or repetitive manufacturing. Consultants are based across Tennessee in Nashville, Memphis, Knoxville, Chattanooga, Jackson, and Tri-Cities.
In a push system, production is scheduled based on forecasts and each process produces according to the plan regardless of whether the next process needs the material. This creates inventory buildup between processes. In a pull system, nothing is produced until the downstream process signals that it needs more. This limits overproduction and keeps inventory controlled at every point in the value stream.
A pilot Kanban loop between two processes can be set up in 2 to 4 weeks. Expanding pull systems across a full value stream typically takes 3 to 6 months as the team builds capability and refines Kanban quantities. Tennessee MEP consultants guide each phase and train your team to manage and adjust the system independently.
Manufacturers implementing Kanban pull systems typically see reduced work-in-process inventory, shorter lead times, fewer stockouts, less overproduction, improved delivery reliability, and simpler scheduling. Pull systems also make problems visible faster because when flow stops the signal system immediately shows where the breakdown occurred.
Cost depends on the complexity of your material flow and number of loops being implemented. Kanban systems themselves require minimal investment since they typically use cards, bins, or simple visual signals. Tennessee MEP provides an initial consultation at no cost to assess your operation. Contact a Tennessee MEP Solutions Consultant for a specific estimate.
Tell us about your production flow — we’ll help you identify where pull systems can reduce inventory and shorten lead times.
On-site consultants across Tennessee — Memphis, Nashville, Knoxville, Chattanooga, Tri-Cities and beyond.