History of Lean

Agile Tour Ho Chi Minh 2012

Kiro HARADA

原田 騎郎Kiro HARADA

Agile CoachDomain ModelerSCM Consultant

Twitter: @haradakiro

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

Toyota Production System (TPS)

What is Toyota Production System (TPS)?

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

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 WorkIncidental WorkNon 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 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

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 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?

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