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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 - PowerPoint PPT Presentation
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What is Lean?
• lean |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
What do you 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
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.
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
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 MuraUnevenness↓
• 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
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 PeopleWhen do you have a strong motivation for work?Survey in Japanese and U.S. automakers showed the same result.
1. Autonomy2. Responsibility3. Achievement4. Opportunity5. The work itself6. Advancement7. Recognition
How can you use Lean / TPS
• In your software development?
• In your organization?
• With your career?
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