Art Smalley
President
Art of Lean, Inc.
1970s
QC
circles!
1980s
Its Kanban!
TPS
2000
Its all about
flow and the
Value Stream!
1990s
Its Kaizen!
Art of
Inc.
Copyright
Lean,
2005 Art
of Lean, Inc.
However
Art of
Inc.
Copyright
Lean,
2005 Art
of Lean, Inc.
Influences
Mass Production
moving conveyor lines
Scientific Principles
Of Management
TPS Development
1937
2006
Standardization
Of Parts
Art of
Inc.
Copyright
Lean,
2005 Art
of Lean, Inc.
Sakichi
Toyoda
Inventor
1890
Wooden
Loom
1896
Auto
Loom
Art of
Inc.
Copyright
Lean,
2005 Art
of Lean, Inc.
1924
Type G
Auto Loom
Art of
Inc.
Copyright
Lean,
2005 Art
of Lean, Inc.
Flow concept
Eiji Toyoda
Taiichi Ohno
Art of
Inc.
Copyright
Lean,
2005 Art
of Lean, Inc.
Honsha
Plant
Machine
Shops
-Engine
-Transmission
-Chassis
Casting &
Forging
Stamping &
Body Weld
Paint
Dept.
Final
Assembly
Art of
Inc.
Copyright
Lean,
2005 Art
of Lean, Inc.
Honsha
Plant
1960
President
Chairman
Kamigo
Plant
1965
Takaoka
Plant
1966
Manufacturing
Quality
Miyoshi
Plant
Tsutsumi
Plant
1968
1970
Product
Development
Art of
Inc.
Copyright
Lean,
2005 Art
of Lean, Inc.
Denso
Kanto
Auto
Central
Auto
Koito
Seisaku
Toyoda
Gosei
Toyoda
Boshoku
Tokai
Rika
Aisan
Kogyo
Taihou
Kogyo
OMCD*
-Kikuo Suzumura
-Fujio Cho
-Others
Jisshuken Activities
1.
2.
3.
4.
5.
Flow production
Standardized work
SMED
JIT/Pull/Kanban
Kaizen
Art of
Inc.
Copyright
Lean,
2005 Art
of Lean, Inc.
Art of
Inc.
Copyright
Lean,
2005 Art
of Lean, Inc.
1950
1970
2003/4
GM
GM
GM
(8.60)
Ford
Ford
Toyota
(7.20)
Chrysler
Chrysler
Ford
(6.72)
Studebaker
VW
VW
(5.11)
Nash
Fiat
Renault*
(4.98)
Kaiser
Toyota
Daimler**
(4.50)
Morris
Nissan
Honda
(2.88)
Hudson
Renault
Hyundai
(2.65)
Austin
BL
Fiat
(2.37)
Renault
Peugeot
Mitsubishi (1.44)
10
...
* Renault/Nissan
** DaimlerChrysler
Source: finance.yahoo.com
Art of
Inc.
Copyright
Lean,
2005 Art
of Lean, Inc.
34
101
27
18
14
44
20
Aspiration:
By 2010
Global
No. 1 with
Market share
Of 15%
1945-55
1955-65
Process flow
JIT
Conveyance
Set up Reduction
Kanban
Jidoka
Production Instruction
Multi-Process Handling
& Standardized Work
1965-75
1975-85
Process flow
JIT
Conveyance
Set up Reduction
Kanban
Ordering System
Jidoka
Production Instruction
Multi-Process Handling
& Standardized Work
6.
7.
8.
Art of
Inc.
Copyright
Lean,
2005 Art
of Lean, Inc.
Eye Glasses
Microscope
Telescope
Blurred image
Small image
Distant image
Clear image
Magnified image
Closer image
TPS Framework
Customer satisfaction
& Company profit
Cost
Lead time
Quality
Takt time?
Continuous flow?
Pacemaker?
Supermarket pull system?
MTO/MTS?
Level production?
Pitch increment?
Process improvements for flow?
(Add in CCF, MMF, CLP, etc.)
Just-in-time
Jidoka
-Flow production
-Takt time
-Pull system
-Level production
Where is the
focus?
Standardized Work & Kaizen
Equipment Stability
*LTS - Learning to See, followed by CCF - Creating Continuous Flow, MMF - Making Materials Flow, & CLP Creating Level Pull
Art of
Inc.
Copyright
Lean,
2005 Art
of Lean, Inc.
TPS Framework
Customer satisfaction
& Company profit
Cost
Lead time
Quality
Takt time?
Continuous flow?
Pacemaker?
Supermarket pull system?
MTO/MTS?
Level production?
Pitch increment?
Process improvements for flow?
Just-in-time
Jidoka
-Flow production
-Takt time
-Pull system
-Level production
*LTS - Learning to See, followed by CCF - Creating Continuous Flow, MMF - Making Materials Flow, & CLP Creating Level Pull
Art of
Inc.
Copyright
Lean,
2005 Art
of Lean, Inc.
Process A
Availability = 65%
Capability = .8 Cpk
Flexibility = 1 Hr. C/O
+ Supervisors
inundated with
other problems
(First 20 years of TPS)
1.
2.
3.
4.
5.
6.
Art of
Inc.
Copyright
Lean,
2005 Art
of Lean, Inc.
Lathe area
1920
40
500
100
40
40
Big
Problem!
Major
Break
Down
1 hour observation
Tool
Minor
Change Stops
CT
Loss
Scrap
Yield
Problem: Machine not producing 1580 parts per shift to meet takt time
Goal:
We must improve 380 parts (1200 to 1580) per shift.
Art of
Inc.
Copyright
Lean,
2005 Art
of Lean, Inc.
1200
2.
The cutting chips fly up in the auto loading chute inside the machine
Art of
Inc.
Copyright
Lean,
2005 Art
of Lean, Inc.
3.
8. Negative rake
angle on the cutting
tool (generates
excessive cutting
force)
6. Bearings worn
Action Items: #4, 6, 7, must be
fixed tonightno exceptions.
#7, #8 investigate further
Art of
Inc.
Copyright
Lean,
2005 Art
of Lean, Inc.
= 1680
Remain =
240
Art of
Inc.
Copyright
Lean,
2005 Art
of Lean, Inc.
Art of
Inc.
Copyright
Lean,
2005 Art
of Lean, Inc.
Art of
Inc.
Copyright
Lean,
2005 Art
of Lean, Inc.
Countermeasures
or analysis tools
On-time delivery
Inventory
Lead-time
VS Mapping
Flow of product
Pull system / kanban
Customer defects
Scrap
Rework
Abnormality detection
Stop the machine
Process Cpk
Capacity losses
Downtime
Scrap & Rework
6 losses
OA / Maintenance
Problem solving
Labor productivity
Scrap & rework
Safety
Job Instruction
Standardized work
Motion analysis
Recurring problems
Firefighting
Poor problem solving
Art of
Inc.
Copyright
Lean,
2005 Art
of Lean, Inc.
TWI/JR
TWI/JI
TWI/JM
PDCA
Root cause analysis
Recurrence prevention
Customer Satisfaction
0 defects
100% value added
1x1, in sequence, on
demand
Human Development
Physical & Mental Safety
Job Security
Professional Challenge
EVERYONE
every minute
every day
Art of
Inc.
Copyright
Lean,
2005 Art
of Lean, Inc.
Appendix
Art of
Inc.
Copyright
Lean,
2005 Art
of Lean, Inc.
Art of
Inc.
Copyright
Lean,
2005 Art
of Lean, Inc.