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LEAN MANAGEMENT (TPS Toyota Production System (Taiichi Ohno (Standard…
LEAN MANAGEMENT
TPS
Toyota Production
System
Sakichi Toyoda
He created an automatic loom
Stops after breaking the thread
Develop 5 WHY
JIDOKA
JIDO
automation
machine that moves on its own
machines stops when finish,
not detect failure
DO
as movement
replaced as:
value added work, which represent people
JIDOKA
automation with a human touch
Kiichiro Toyoda
In 1929 he goes to USA to check and learn
the manufacturing of a cars.
Just-in- time
What is needed
When is needed
Amount is needed
First car TOYOTA - A1
Taiichi Ohno
Improved and re-implement
JIDOKA
Reduction of weste
Implement
just-in-time principles
Smaller batches of parts to be used
Has been sent to USA to see automotive plants and was impressed, fascinated by the supermarkets
KAN-BAN
Standard work
Active cooperation with the people
from the work place - GEMBA
Ans ask to change forget
old way of working
Empowered workers to stop the line
Encourage their workers
to propose improvement
Production Manager
WWII - automotive production in
USA is 8 times bigger than in Japan
JAPAN:
Lack of resources
JAPAN:
Lack of people and knowledge
JAPAN:
Lack of capital and equipment
Eiji Toyoda
#
He saw FORD plants and decided
it will not fit to Japanese way of thinking
W. Edwards Deming
1900 - 1993
PDCA
PDSA
S- STUDY the effect of DO
A - AKT or ADJUST
Quality First
Doing things right the first time
Henry Ford
Ford T
1908
First moving assembly line
In XVI (1574) century in Venetian
Arsenal they use first assembly line
to manufacture their war ships
First example of FLOW PRODUCTION
along a canal
They built complete naval galley in under 1 hour
Standardized design
Interchangeable parts
części wymienne
WASTE:
OVERPRODUCTION
Frequent changeover
caused big stok
Customer asked for diversity
Different model
Different colors
Special mathematics formula
Mathematic calculation of batch size
to minimanilize the cost of changeover
Not by customer needs
Constantly improvements of the line
START: 12 h to assembly 1 car
END: 90 min to assembly 1 car
You can have any color you want
as long as it is black
Paint: low price/ good quality/
fast drying
Frederic Taylor
1859-1915
Principles of
scientific management
Work Standarization
He defined,
that there is a perfect method to do a work