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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

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History of Lean

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  1. History of Lean Agile Tour Ho Chi Minh 2012 Kiro HARADA

  2. 原田騎郎 Kiro HARADA Agile Coach Domain Modeler SCM Consultant Twitter: @haradakiro

  3. 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

  4. 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

  5. Toyota Production System (TPS) What is Toyota Production System (TPS)?

  6. What do you know about TPS? • Just In Time • Kanban • Muda • Heijunka • Andon • 5S (Seiri, Seiton, Seisou, Seketsu, Shituke) • Go and See (GenchiGembutsu) • 5 Times Why • Jidoka • Kaizen • Pull • SMED(Single Minute Exchange of Dies) • 1 piece flow • Value Stream Mapping • Takt Time

  7. House of TPS Quote from S. Kuroiwa

  8. Toyoda Type G Automatic Loom (1924) http://commons.wikimedia.org/wiki/File:1924_Non-Stop_Shuttle_Change_Toyoda_Automatic_Loom,_Type_G_1.jpg

  9. Toyoda Type G Automatic Loom (1924) 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. http://commons.wikimedia.org/wiki/File:1924_Non-Stop_Shuttle_Change_Toyoda_Automatic_Loom,_Type_G_1.jpg

  10. How did Toyota come up with TPS?

  11. 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.

  12. TPS Core Concepts • Autonomation (Autonomous Automation) • Just in time • SMED • Kanban • Self Management • People Development

  13. Value Stream Mapping (Figure to be Added) Map of Value Added Work

  14. Value Added Work

  15. 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

  16. 7 Wastes – 7 Muda • Transportation • Inventory • Motion • Waiting • Over-processing • Over-production • Defects

  17. 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.

  18. Continuous Flow • Leveled Production – Heijunka (平準化) • Muri – Mura – Muda are eliminated end to end

  19. Kanban

  20. Kaizen • Continuous Improvement • Eliminate • Combine • Replace • Simplify

  21. 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

  22. All about People When do you have a strong motivation for work? Survey in Japanese and U.S. automakers showed the same result. • Autonomy • Responsibility • Achievement • Opportunity • The work itself • Advancement • Recognition

  23. How can you use Lean / TPS • In your software development? • In your organization? • With your career?

  24. Think Yourself In Your Context

  25. Because TPS stands for Thinking People’s System

  26. Thank you “Open the door, it’s a large world outside.” Sakichi Toyoda

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