Module 7 · Lesson 11 of 24

Pull systems and WIP limits

Learning objectives

Explain the purpose of pull systems and wip limits in garment operations.
Describe when and how to apply pull systems and wip limits on the shop floor.
Identify common mistakes and how to avoid them.

Core idea

Pull authorizes upstream work from downstream consumption; WIP limits expose problems and control lead time.

Method

Stabilize process, define pacemaker and container, size WIP from demand/replenishment/variation, specify signal and exception response. Never cut WIP without reliability and recovery planning.

Garment-factory example

A finishing supermarket triggers sewing release by style/size/colour rather than pushing all cut bundles at once.

Method

Stabilize process, define pacemaker and container, size WIP from demand/replenishment/variation, specify signal and exception response

Common mistakes

Never cut WIP without reliability and recovery planning

Knowledge check

Pick one answer per question. Explanations appear after you submit.

1. Which statement best captures the core idea of Pull systems and WIP limits?
- Pull authorizes upstream work from downstream consumption; WIP limits expose problems and control lead time.
- It is a purely financial control unrelated to shop-floor work.
- It replaces the need for standardized work and training.
- It applies only to fully automated factories.
2. A common mistake when applying pull systems and wip limits is to:
- Never cut WIP without reliability and recovery planning
- Involve operators and validate with data.
- Link the tool to the observed problem and follow-up plan.
- Update the standard after a confirmed improvement.

Author: Sanjeewa Dehiwalage · Last reviewed: 2026-07-21

Learning objectives

Core idea

Method

Garment-factory example

Method

Common mistakes

Knowledge check

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