Lean into KaizenLean into Kaizen

An introduction to theAn introduction to theToyota Production SystemToyota Production System

And Lean ProductionAnd Lean Production

IntroductionIntroduction The Toyota Production System was created The Toyota Production System was created

by Taiichi Ohno starting in the 1940'sby Taiichi Ohno starting in the 1940's It is the foundation for what has become It is the foundation for what has become

known as Lean Manufacturing in the USknown as Lean Manufacturing in the US It was credited with being the reason Toyota It was credited with being the reason Toyota

was able to survive Japanese reconsdtructionwas able to survive Japanese reconsdtruction Its basis is the reduction of waste, Its basis is the reduction of waste,

continuously improving, and organized flowcontinuously improving, and organized flow

The Main AspectsThe Main Aspects Continuous Continuous

Improvement Improvement (Kaizen, Gemba)(Kaizen, Gemba)

Organized Flow (Andon, 5S, Standard Work)

Just in Time Production (Takt and Kanban)

Reduction of Waste (Muda)

Continuous ImprovementContinuous Improvement Continuously improving processes (Kaizen) Continuously improving processes (Kaizen)

creates reduced cost and effort.creates reduced cost and effort. Gemba WalksGemba Walks: Gemba walks are where : Gemba walks are where

leaders go onto the floor and discuss a leaders go onto the floor and discuss a process. Get down and dirty to try and process. Get down and dirty to try and understand it better, and look for possible understand it better, and look for possible improvements.improvements.

Idea ProgramsIdea Programs: This allows employees to : This allows employees to take more ownership of a process. Nobody take more ownership of a process. Nobody knows how to do a job better than those who knows how to do a job better than those who always do it, and they can find always do it, and they can find improvements to be proud of.improvements to be proud of.

Ideas for ImplementationIdeas for Implementation Create an idea program for in process Create an idea program for in process

employees.employees. Require management to learn processes Require management to learn processes

to look for improvement.to look for improvement. Do mixed Kaizen Events with both lower Do mixed Kaizen Events with both lower

level and upper level employees to level and upper level employees to analyze a process for improvement/ analyze a process for improvement/ waste reducing ideas.waste reducing ideas.

Organized FlowOrganized Flow 5S5S: Sort, Set in Order, Shine, Standardize, Sustain. : Sort, Set in Order, Shine, Standardize, Sustain.

This creates an organized workplace with little This creates an organized workplace with little misplacement, and easliy spotable defects.misplacement, and easliy spotable defects.

AndonAndon: This is a method for immediately alerting : This is a method for immediately alerting management or downsteam processes of a management or downsteam processes of a problem. It normally consists of a warning light.problem. It normally consists of a warning light.

Standard WorkStandard Work: Standardizing work makes work : Standardizing work makes work more memorizable and creates less more memorizable and creates less variation/defects.variation/defects.

Ideas for ImplementationIdeas for Implementation Create a standard location for all tools and Create a standard location for all tools and

supplies.supplies. Create a beacon or email notification system Create a beacon or email notification system

for alerting the rest of the team of problems.for alerting the rest of the team of problems. The Japanese set aside time for cleaning and The Japanese set aside time for cleaning and

organizing, this lets everyone get together, organizing, this lets everyone get together, get everything organized, and gets people get everything organized, and gets people closer to the ground level to spot defects.closer to the ground level to spot defects.

Reduction of The 7 WastesReduction of The 7 WastesOne of the main One of the main

purposes of TPS/Lean purposes of TPS/Lean is reduction of the 7 is reduction of the 7 wastes (muda). Any wastes (muda). Any reduction of overuse reduction of overuse is considered an is considered an improvement on a improvement on a process. Essentially, process. Essentially, how will each piece how will each piece or action influence or action influence the customer?the customer?

Overtransportation Overinventory/Supply Motion Waiting/ Waste of Time Overproduction Over Processing &

Unnecissary Actions Defects

Ideas for ImplementationIdeas for Implementation What supplies do you have to many of for that What supplies do you have to many of for that

days work?days work? Who has to move around/ work the hardest in Who has to move around/ work the hardest in

their process? Is it taking them more time?their process? Is it taking them more time? Is every piece and process REALLY benefitting Is every piece and process REALLY benefitting

the customer?the customer? Some companies don't have chairs, as it Some companies don't have chairs, as it

requires more motion, and standing/stretching requires more motion, and standing/stretching while at a desk allows clearer thought and ideas while at a desk allows clearer thought and ideas (thats why you have your best ideas in the (thats why you have your best ideas in the shower!)shower!)

Just in Time ProductionJust in Time ProductionTiming is everything. By making goods as they are Timing is everything. By making goods as they are

ordered or only creating buffers of what you ordered or only creating buffers of what you KNOW will need to be shipped, you can reduce KNOW will need to be shipped, you can reduce production hours, reduce storage space (and production hours, reduce storage space (and therefore costs), and reduce the costs of parts. therefore costs), and reduce the costs of parts.

Many companies take this further by creating a Many companies take this further by creating a rate for employee to benchmark how much work rate for employee to benchmark how much work should be done in a given time. This way you can should be done in a given time. This way you can standardize output and see whos working hard!standardize output and see whos working hard!

Ideas for ImplementationIdeas for Implementation Create rates that employees must meet. This Create rates that employees must meet. This

will let you know how much you can produce in will let you know how much you can produce in a given time.a given time.

Create a organize resupply structure. Only Create a organize resupply structure. Only resupply when needed, and know how long it resupply when needed, and know how long it takes to get those supplies (this cuts storage takes to get those supplies (this cuts storage and buying costs).and buying costs).

Resupply Cards (Kanban cards) can be used, or Resupply Cards (Kanban cards) can be used, or automatic low inventory emails will work. Then automatic low inventory emails will work. Then you never run out, but never keep too much!you never run out, but never keep too much!