student version Ch8

student version Ch8 - MGMT 361 Operations Management (OM)...

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1 MGMT 361 Operations Management (OM) Chapter 8 Lean Manufacturing Prof. Julia A. Kalish
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2 Lean Manufacturing System** Toyota Manufacturing System Kanban system Pull System Just-In-Time System Stockless Production System ** Coined in 1990 by James Womack and Daniel Roos in their book, The Machine That Changed the World One System – Many Names:
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Major Revolutions in Manufacturing 1776, Adam Smith “The Wealth of Nations” (Industrial Revolution). 1910, Henry Ford and Mass Manufacturing. • 1980, The Toyota Production System-lean manufacturing. SMED (Single minute exchange of Die): changeovers should take less than 10 minutes (i.e., single digit minute) Deming’s quality movement in Japan. The engineers : Shigeo Shingo & Taiichi Ohno . “Japanese” Manufacturing hits America. 2010, gas pedal sticking problem (millions of Toyota models recalled and halted the sales of more than half of US models. ???
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4 The Toyota Production System Part I: Just-in-Time Production Doing it all for the customer Leveled production Running a Pull system Continuous flow processing Takt Time Multi-skilled operators Part II: Jidoka Building quality into the Production Process Part III: Standardized work and Kaizen Standardized work – Basis for kaizen Kaizen: The Lifeblood of Standardized Production.
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5 1931 – technician in a railway factory 1943 – Manufacturing Section Chief in Amano Manufacturing Plant. Raises productivity by 100% applying flow operations . 1946 – Working at Hitachi, discovers that processes and operations are inseparable. 1950 – Furkawa Electric: develops SMED concept (single minute exchange of die). 1955 – Joined Toyota . Has been responsible for many improvements. Introduced SMED, POKA-YOKE system of mistake-proofing. He has written 14 major books and hundreds of important papers on manufacturing . The Shingo Prize is awarded for excellence in manufacturing as a tribute to Dr. Shingo and his lifelong work. Shigeo Shingo (1909 -1990)
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6 Taiichi Ohno (1912-1990) Considered to be the most influential person in the development of Toyota Manufacturing System . 1. Produce only what the market demands. 2. Visual aids to highlight where action is needed. 3. Small batch sizes. Pull System : Idea based on visit to grocery stores in the USA.
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