History of Lean
Agile Tour Ho Chi Minh 2012
Kiro
HARADA
原田
騎郎
Kiro
HARADA
Agile Coach
Domain Modeler
SCM Consultant
Twitter: @
haradakiro
What is Lean?
•
l
ean
|
liːn
|
•
Adjective
•
(of a person or animal) thin, especially healthily so;
having no superfluous fat:
his lean, muscular body
.
•
(of meat) containing little fat:
lean bacon
.
•
(of an industry or company) efficient and with no
wastage:
staff were pruned, ostensibly to produce a
leaner and fitter organization
.
Oxford English Dictionary
Origin of Lean
•
1988
-
Paper “Triumph of Lean
Production System”
–
Study on Toyota Production System
•
International Motor Vehicle
Program(IMVP) at MIT Sloan
School
•
1990
-
The Machine That Changed
The World
–
James P. Womack
–
Toyota was ½ size of GM
Toyota Production System (TPS)
What is Toyota Production System (TPS)?
What do
y
ou know about TPS?
•
Just In Time
•
Kanban
•
Muda
•
Heijunka
•
Andon
•
5S (
Seiri
,
Seiton
,
Seisou
,
Seketsu
,
Shituke
)
•
Go and See (
Genchi
Gembutsu
)
•
5 Times Why
•
Jidoka
•
Kaizen
•
Pull
•
SMED(Single Minute Exchange of Dies)
•
1 piece flow
•
Value Stream Mapping
•
Takt
Time
House of TPS
Quote from S.
Kuroiwa
Toyoda Type G Automatic Loom (1924)
http://
commons.wikimedia.org
/wiki/File:1924_Non
-
Stop_Shuttle_Change_Toyoda_Automatic_Loom,_Type_G_1.jpg
Toyoda Type G Automatic Loom (1924)
http://
commons.wikimedia.org
/wiki/File:1924_Non
-
Stop_Shuttle_Change_Toyoda_Automatic_Loom,_Type_G_1.jpg
What was different from other Looms?
•
Non
-
stop Shuttle Change
•
Automatically STOPs if a thread breaks
Throughput of Manufacturing Good Product is far
more important than the Machine Utilization Rate.
Toyoda sold
Patenet
of Type G and used to seed
Toyota Motors Co. Ltd.
How did Toyota come up with TPS?
Toyota was almost bankrupt
In 1950,
a major labor dispute in Toyota Motor.
Most of Executives including the founder
Shoichiro
Toyoda resigned.
Toyota has no money to buy
enough
machines,
lines, parts and hire managers at that time.
TPS Core Concepts
•
Autonomation
(Autonomous Automation)
•
Just in time
–
SMED
–
Kanban
•
Self Management
•
People Development
Value Stream Mapping
(Figure to be Added)
Map of Value Added Work
Value Added Work
Value Added Work
Incidental Work
Non Value Added Work
Autonomation
Autonomous Automation
Automation with Human Intelligence
(Build Quality
In)
自動化
(Automation)
自働化
(
Autonomation
)
•
Automation to improve operational ratio
•
Autonomation
to improve through
-
put
7 Wastes
–
7
Muda
•
Transportation
•
Inventory
•
Motion
•
Waiting
•
Over
-
processing
•
Over
-
production
•
Defects
Muri
Mura
Muda
•
ムリ
Muri
Overload / Overburden
↓
•
ムラ
Mura
Unevenness
↓
•
ムダ
Muda
Waste
You need to eliminate
Muri
first with KAIZEN to
eliminate
Muda
.
Continuous Flow
•
Leveled Production
–
Heijunka
(
平準化
)
•
Muri
–
Mura
–
Muda
are eliminated end to end
Kanban
Kaizen
•
Continuous Improvement
•
Eliminate
•
Combine
•
Replace
•
Simplify
The Five S’s (5S)
•
Seiri
–
sort, sort out, organize
•
Seiton
–
straighten, stabilize, make it neat
•
Seiso
–
scrub, shine, clean
•
Seiketsu
–
systemize, standardize
•
Shitsuke
–
sustain, self
-
discipline, discipline
All about People
When do you have a strong motivation for work?
Survey in Japanese and U.S. automakers showed the
same result.
1.
Autonomy
2.
Responsibility
3.
Achievement
4.
Opportunity
5.
The work itself
6.
Advancement
7.
Recognition
How can you use Lean / TPS
•
In your software development?
•
In your organization?
•
With your career?
Think Yourself
In Your Context
Because TPS stands for
Thinking
People’s System
Thank you
“Open the door, it’s a large world outside.”
Sakichi
Toyoda
Enter the password to open this PDF file:
File name:
-
File size:
-
Title:
-
Author:
-
Subject:
-
Keywords:
-
Creation Date:
-
Modification Date:
-
Creator:
-
PDF Producer:
-
PDF Version:
-
Page Count:
-
Preparing document for printing…
0%
Σχόλια 0
Συνδεθείτε για να κοινοποιήσετε σχόλιο