Implementing an Order Pull System into a Medical Device Company Using Define for Lean Six Sigma Methodology

Overview & Synopsis

This project aims to show how implementing continuous flow pull production with just-in-time Kanban processes in a Medical Device company can improve customer supply and thus mitigate device shortages in the Medtech supply chain. A case study in a medical device manufacturer utilised Define for Lean Six Sigma methodology for the design of a pull process and identification of waste in the process by using Value Stream Mapping and Kaizen events. A Pull model utilising Kanban and Hejunka was designed and implemented to produce products based only on customer demand signals. The device aged work orders in the process and waste reduced and overall service to the customer was improved while ensuring products were produced based on customer demand signals resulting in lead time and inventory reduction of over 60%, increased inventory turns, elimination of waste due to overproduction, holding inventory, and increased collaboration and communication between stakeholders. This is one of the few studies on implementing a Lean pull model in a medical device manufacturer and can be leveraged to improve supply chain accuracy and reliability. This study can demonstrate how supply chain shortages in devices that may affect patient treatments can be mitigated by embracing Lean methods.