Push System

Introduction: Push System

A Push system is a traditional production model where goods or services are produced according to a pre-determined schedule or plan, rather than actual customer demand. Materials, orders, and information are “pushed” through the production chain based on forecasts, regardless of whether the next process step is ready or demand exists.

Background

Push systems have long been used in manufacturing and service industries, particularly where planning and efficiency were prioritised over flexibility. While this approach can stabilise production in predictable environments, it often conflicts with Lean principles, which emphasise demand-driven flow and waste reduction.

Key Elements/Features

• Pre-Determined Planning: Activities scheduled based on forecasts and estimates.
• Forced Flow: Materials and orders are moved forward even if the next process is not ready.
• Efficiency-Oriented: Focus on maximising output, sometimes at the expense of flow and demand alignment.

Applications/Examples

• Mass Production: Traditional assembly lines producing large batches ahead of demand.
• Seasonal Goods: Manufacturing products in advance to meet predictable peaks (e.g., holiday items).
• Complex Production: Industries where long lead times require planning far ahead.

Relevance/Impact

Push systems often lead to inefficiencies:

• Overproduction: Producing more than needed, resulting in excess stock.
• High Inventory Costs: Increased storage and handling due to surplus goods.
• Waste: Resources consumed on items not immediately required.

Comparison with Pull Systems

• Push: Driven by forecasts, higher risk of overproduction, less flexible.
• Pull: Driven by actual demand signals, lower inventory, aligned with Lean and Just-in-Time (JIT) methods.

When to Use Push Systems
Push can be effective when demand is stable, predictable, or when production complexity limits responsiveness. In such cases, a well-planned push approach can still deliver efficiency.

See also

• Pull System
• Just-in-Time (JIT)
• Kanban
• Kanban Card