History of Lean

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