History of Lean

possehastyMechanics

Nov 5, 2013 (3 years and 9 months ago)

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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