Lean Pull & Kanban: How to Make Flow Visible and Eliminate Overproduction: Toyota Production System Concepts
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About this ebook
Pull production starts where most systems end — with the customer.
Unlike traditional production where products are pushed into the market hoping someone will buy, pull production begins by listening to what is actually needed — how much, when, and where.
In this clear and practical guide, Dr. Mohamed H. Soliman explains how pull systems work, how they reduce overproduction, and how they connect to Just-in-Time (JIT) as part of Toyota's lean philosophy.
You'll learn:
- How downstream steps signal upstream steps for what is needed
- Why pull is the opposite of "make-to-stock" thinking
- The role of Kanban as the visual tool that enables pull
- How Pull, Takt, and Flow form the three pillars of JIT
- Why Heijunka (Leveling) is the foundation behind them all
- Real examples of pull in factories and service organizations
Whether you are just starting with Lean or improving an existing system, this book gives you the mindset, methods, and steps to make Pull Production work in the real world.
Because flow starts with demand — not guesswork.
Mohammed Hamed Ahmed Soliman
Dr. Mohammed Hamed Ahmed Soliman is an internationally recognized Lean expert, author, and university lecturer. He has published over 100 books and articles on Lean thinking, quality systems, and industrial excellence. He currently teaches Industrial Engineering and Management Systems at the American University in Cairo, an Executive Advisor and a member of the Advisory Committee of the IEOM International Society, and consults for global organizations across manufacturing, public services, and education. With nearly two decades of academic and professional experience, Dr. Soliman has trained professionals across the Middle East, including engagements with Princess Nourah University in Saudi Arabia and Vale Oman Pelletizing Company. He has designed and delivered over 60 leadership and technical development programs, helping organizations build a culture of continuous improvement and operational excellence. Earlier in his career, he worked in various industrial sectors including crystal-glass manufacturing, fertilizers, and chemicals, while educating teams on the Toyota Production System. He has led numerous lean transformation projects, delivering measurable results and uncovering substantial cost savings by targeting waste across production and service environments. His lectures and training materials have reached over 200,000 learners via SlideShare, and his research is ranked among the most downloaded papers on the Social Science Research Network (SSRN) by Elsevier. Dr. Soliman holds a BSc in Engineering, a master's in Quality Management, and postgraduate degrees in Industrial Engineering and Engineering Management. He also holds certifications in quality, cost, and operations management. He is a member of the Institute of Industrial and Systems Engineers (IISE) and the Society for Engineering and Management Systems (SEMS). His insights have been featured in SAGE Publications, Industrial Management, Lean Thinking, and other peer-reviewed platforms.
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Lean Pull & Kanban - Mohammed Hamed Ahmed Soliman
Lean Pull & Kanban: How to Make Flow Visible and Eliminate Overproduction
Toyota Production System Concepts
Mohammed Hamed Ahmed Soliman
Published by personal-lean.org, 2023.
While every precaution has been taken in the preparation of this book, the publisher assumes no responsibility for errors or omissions, or for damages resulting from the use of the information contained herein.
LEAN PULL & KANBAN: HOW TO MAKE FLOW VISIBLE AND ELIMINATE OVERPRODUCTION
First edition. October 26, 2023.
Copyright © 2023 Mohammed Hamed Ahmed Soliman.
ISBN: 979-8215942802
Written by Mohammed Hamed Ahmed Soliman.
Toyota Production System Concepts
Lean Pull System and Kanban
By Mohammed Hamed Ahmed Soliman
Contents
The Beginning
The Pull Concept is the Opposite of the Push Concept
Lean Pull is a Concept That Helps to Streamline the Flow of Materials in a Simple and Efficient Manner
The Lean Pull System Needs Everyone to Work Together
What is Kanban and How Does it Work
Kanban and Healthcare Industry
Making the System Function Correctly
Flow, Pull, and Eliminate Waste
The Beginning
For many years, production has used the old method of mass production created by Henry Ford. This means that parts are made in large groups and then sold to customers, hoping that someone will buy them. The success of something depends on predicting the future and the sales predictions were overly positive. This system separates the factory from the customer. The factory is only making products based on a predicted amount. The customer process, which is also