Pull Signal Calculations

Standard Pack:

1 standard pack = 1 container = 1 pull signal

1 days production = ( )
1 standard pack = 1 days production / 10
( ) = ( ) / 10

Maximum Inventory Level (Max):

Weekly average = 8 weeks inventory / 8

( ) = ( ) / 8
Days of inventory = weekly average / planned daily production
( ) = ( ) / ( )
Safety stock *s.s.) = additional inventory that must be added due
to current non-synchronized operations.
MAX = (days of inventory) X (daily planned production) + (s.s.)
( ) = ( ) X ( ) + ( )

Minimum inventory level (MIN):

(MIN) = batch size = red zone = replenishment

(MIN) = ( )

Number of Pull Signals in a Loop (nps)*:

(nps) = (MAX) / number of pieces in a standard pack

( )* = ( ) / ( )

Number of Pull Signals in a Red Zone (RZ)*:

(RZ) = (MIN) / pieces in a standard pack

( )* = ( ) / ( )

Number of Pull Signals in a Yellow Zone (YZ)*:

(YZ) = (nps) - (RZ) / 2

( )* = (( ) - ( )) / 2

Number of Pull Signals in a Green Zone (GZ)*:

(GZ) = (nps) - (RZ) - (YZ)

( ) = ( ) - ( ) - ( )

Designated Storage (dss):

(dss) = (nps) X (length) X (width) / number of containers high

( ) = ( ) X ( ) X ( ) / ( )

* Round up to the next highest number

/ Means divided by

X Means multiplied by

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This is a worksheet for determining the number of pull signals, storage quantity, red/yellow/green quantities, etc. Use as a reference. Remember it is important that the customer and supplier discuss together the determination and execution of the pull

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