A push-to-pull conversion case study — a worked kanban card and container-quantity calculation, two-bin cycle mechanics, and a before/after comparison of WIP and lead time built directly on Little's Law.
The project brief: a sub-assembly work center scheduled entirely by a weekly MRP batch release is replacing that push schedule with a two-bin kanban pull loop. Framed as this program's clearest inventory-control case study, every number in this module traces back to one demand rate and one replenishment lead time.
This module walks the whole conversion the way a real industrial engineer would: the measured push-system WIP and lead time, the standard K = D×L×(1+S)/C kanban card formula worked in full, the two-bin cycle's structural WIP ceiling, and the Little's Law identity that makes the WIP reduction and the lead-time reduction come out to exactly the same percentage. The full worked numbers and finished design reasoning are part of the unlocked module below.