Lean

OPS 370

Videohttps://www.youtube.com/watch?v=J4v-HjY3R0Y

6:28 duration

Toyota and Lean Thinking

• Toyota’s President, Katsuaki Watanabe said, “What is important is to be number one in quality.”

• Toyota sold 1.6 million vehicles in 2011 (Even with Earthquake/Tsunami Supply Chain Disruptions)

• Uses production philosophy Toyota Production System (TPS) or lean production.

• Toyota pioneered “just-in-time” manufacturing Suppliers send parts frequently (carry little inventory)

What is Lean Production?

Reduce Variability

Inventory level

Process downtimeScrap

Setup time

Late deliveries

Quality problems

Inventory level

Reduce Variability

Process downtimeScrap

Setup time

Late deliveries

Quality problems

Inventory level

Reduce Variability

Process downtime removed

No scrap

Setup time

reducedLate

deliveries

Quality problems removed

Lean Production Core Components

Eliminating Waste

General Types of Waste

Components of Lean Production Systems

Pull Production System

Small Batch Sizes

Short Setup Times

Just-In-Time Inventory

Uniform Production Planning

Continuous Improvement or Kaizen

Close Supplier Relationships

Multifunctional Work Force

Five S

Visual Controls

Preventive Maintenance

Value Stream Mapping

Pull Production System

Small Batch Sizes and Short Setup Times

Just-In-Time Inventory

Uniform Production Planning

Continuous Improvement or Kaizen

Close Supplier Relationships

Five S

Five S

Visual Controls

Preventative Maintenance

Value Stream Mapping (VSM)