Pull System Simulator
Kanban cards and material replenishment
Two-card replenishment loop
Totes are stocked at both processes
Scroll the factory sideways to follow the flow.
Other Kanban signals
Two ways to authorize replenishment.
Supermarket
6 / 6 totesOne tote holds four parts.
Consume stock
Withdraw a tote to supply the next process.
6 totes availableWithdrawals release the cards at the marked levels.Bring raw material
The material card is released when four totes remain.
Waiting for the material cardDelivery prepares the machine for the next batch.Produce a batch
The production signal is released when two totes remain.
Waiting for the production signalBoth material and authorization are required.
Withdraw totes to reach the material and production thresholds.
Why use separate signals?
The material card arranges delivery before the production lot is needed. The production signal authorizes a batch of four totes. Having raw material ready does not itself authorize production.
What is a pull system?
A pull system controls production and material movement using signals from the process that consumes the material. In a Kanban system, each signal authorizes a specified quantity to be produced or transferred.
The simulator shows fabrication, a supermarket and assembly. The supermarket is a controlled stock of completed parts between the two processes. Assembly withdraws parts from this stock, and fabrication replaces the quantity withdrawn.
How the cards work
- Production cards authorize fabrication to produce one tote of parts. They remain attached to completed totes in the supermarket until those totes are withdrawn.
- Move cards authorize the transfer of totes from the supermarket to assembly. In this simulation, assembly releases a move card when its tote is empty.
At the supermarket, the material handler replaces the production card on a full tote with a move card. The tote goes to assembly. The production card returns to fabrication to authorize a replacement.
How to use this tool
- Select Follow the cards to step through a replenishment cycle.
- Select Run the factory to advance the simulation. Change the card quantities, production time or collection interval and compare inventory with orders fulfilled on time.
- Select Other signals to examine signal and material cards or Kanban squares.
Frequently asked questions
- What happens when a card is removed?
- The number of authorized totes decreases. A card attached to a full tote is removed when that tote is withdrawn from the supermarket. Fewer cards can reduce inventory, but may also cause shortages if replenishment is too slow.
- Why does assembly run out of parts?
- Assembly runs out when its stock is consumed before replacement material arrives. Collection delays, production time, machine stops and defects can all delay replenishment.
- How are results saved?
- Save this run stores a comparison while the page is open. Restart with new starting conditions to compare runs of the same duration. Download Printout creates a snapshot of the current activity. Resetting the simulation or refreshing the page clears the saved comparison.
Related tools
- Kanban Card Calculator — calculate card quantities from demand, replenishment time and container size.
- Milk Run Planner — calculate collection and delivery route times.
- PFEP Builder — record part quantities, containers and replenishment requirements.