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.
