lean production-system

A Brief History of Car ManufacturingA Brief History of Car Manufacturing

Invention of Automobile in 1880Invention of Automobile in 1880

The Henry Ford Mass Production SystemThe Henry Ford Mass Production System

The Toyota or Lean Production SystemThe Toyota or Lean Production System

Toyota Production System


Carl Benze

Gotlib Daimler

Invention of AutomobileInvention of Automobile Carl Benz is generally given credit to Carl Benz is generally given credit to

develop world first automobile in 1985develop world first automobile in 1985

Gotlib Daimler is also contemporary of Gotlib Daimler is also contemporary of Carl Benz who is simultaneously Carl Benz who is simultaneously developed the automobile with him.developed the automobile with him.

Other contemporaries are Wilhelm Other contemporaries are Wilhelm Maybach and Seigfried Marcus known Maybach and Seigfried Marcus known for developing automobile later during for developing automobile later during the same period.the same period.


Carl Benze

Gotlib Daimler Replica of the Benz Patent Motorwagen built in 1886


Carl Benze

Gotlib Daimler Carl Benze First Motorcyle


Carl Benze

Gotlib Daimler


Carl Benze

Gotlib Daimler Carl Benze “Vilo” Model of 1894

Henry Ford’s Mass Production SystemHenry Ford’s Mass Production System In 1910 Henry Ford laid the foundation of first highly In 1910 Henry Ford laid the foundation of first highly

organized assembly line system of automobile organized assembly line system of automobile manufacturing.manufacturing.

He organized all the elements of a manufacturing He organized all the elements of a manufacturing system-- people, machines, tooling, and products-- system-- people, machines, tooling, and products-- and arranged them in a continuous system called and arranged them in a continuous system called conveyer system for manufacturing the Model-T conveyer system for manufacturing the Model-T automobile.automobile.

Ford was so incredibly successful he quickly became Ford was so incredibly successful he quickly became one of the world's richest men and put the world on one of the world's richest men and put the world on wheels.wheels.

Ford Motor Company produced “A-Bomber an Hour” Ford Motor Company produced “A-Bomber an Hour” during WWII for USAF using the same concept.during WWII for USAF using the same concept.


Ford Motor Company’s Production LinesFord Motor Company’s Production Lines


Henry Ford Introduced Conveyer Belt System in Automotive IndustryHenry Ford Introduced Conveyer Belt System in Automotive Industry


A bomber an hour: Assembly in Ford Motor CompanyA bomber an hour: Assembly in Ford Motor Company

B-24 bomber final assembly area at Ford Motor Company's Willow Run plantB-24 bomber final assembly area at Ford Motor Company's Willow Run plant


Toyoda Family in Auto IndustryToyoda Family in Auto Industry The Allied victory and the massive quantities of material The Allied victory and the massive quantities of material

behind it (“A Bomber an Hour” success) caught the attention behind it (“A Bomber an Hour” success) caught the attention of Japanese industrialists.of Japanese industrialists.

Toyoda family were among those Japanese industrialists who Toyoda family were among those Japanese industrialists who were observing American industrial strength and wanted to were observing American industrial strength and wanted to emulate it by investing in Automotive Industry.emulate it by investing in Automotive Industry.

Toyoda Automatic Loom Company, under the encouragement Toyoda Automatic Loom Company, under the encouragement of the Japanese government, which needed domestic vehicle of the Japanese government, which needed domestic vehicle production partly due to the worldwide money shortage and production partly due to the worldwide money shortage and partly due to the war with Chinapartly due to the war with China

The Toyota Motor Corporation was founded in September The Toyota Motor Corporation was founded in September 1933 when Toyoda Automatic Loom created a new division 1933 when Toyoda Automatic Loom created a new division devoted to the production of automobiles under the direction devoted to the production of automobiles under the direction of the founder's son, Kiichiro Toyoda.of the founder's son, Kiichiro Toyoda.


Kiichiro Toyoda

The first production model AA in 1936

Toyota Learns From the Ford Motor CompanyToyota Learns From the Ford Motor Company

Toyota found it difficult to emulate Ford Motor Company whose Toyota found it difficult to emulate Ford Motor Company whose production system was based on Mass Production System.production system was based on Mass Production System.

Post WWII Japanese economy was in shambles and Toyota could Post WWII Japanese economy was in shambles and Toyota could not afford Mass Production of vehicles due to smaller market size.not afford Mass Production of vehicles due to smaller market size.

Toyota’s top bosses begin to design a whole new concept of Toyota’s top bosses begin to design a whole new concept of Production System which is now also known as Just-in-Time Production System which is now also known as Just-in-Time system.system.


At Toyota Motor Company, At Toyota Motor Company, Taichii OhnoTaichii Ohno and and Shigeo ShingoShigeo Shingo, are known as the brain , are known as the brain behind transforming Ford production and behind transforming Ford production and other techniques into an approach calledother techniques into an approach called Toyota Production System Toyota Production System or Lean or Lean Production System or Production System or Just-in-Time System.Just-in-Time System.

Taichii Ohno was the Production Boss of Taichii Ohno was the Production Boss of Toyota Motor Corporation and Shigeo Shigo Toyota Motor Corporation and Shigeo Shigo was industrial engineer and consultant of was industrial engineer and consultant of Toyota Motor Corporation.Toyota Motor Corporation.


Taichii Ohno

Shigeo Shingo

http://www.strategosinc.com/just-in-time_production.htm

Ford vs. Toyota model of Production SystemFord vs. Toyota model of Production System

Can be best explained as:Can be best explained as:

Mass Production vs. Lean (JIT) ProductionMass Production vs. Lean (JIT) Production


What is Mass Production SystemWhat is Mass Production System

Mass productionMass production is the name given to the is the name given to the method of producing goods in large method of producing goods in large quantities at low cost per unit.quantities at low cost per unit.

This system of production is also known This system of production is also known as Push System or Just-in-Case System.as Push System or Just-in-Case System.

To make it worthwhile, mass production To make it worthwhile, mass production requires mass consumption.requires mass consumption.

With precision equipment, large numbers With precision equipment, large numbers of identical parts could be produced at low of identical parts could be produced at low cost and with a small work force. cost and with a small work force.


What is Lean Production System?What is Lean Production System?

Lean Production System is the system Lean Production System is the system designed and evolved in Toyota Motor designed and evolved in Toyota Motor Corporation.Corporation.It is the modified form of Henry Fords Mass It is the modified form of Henry Fords Mass Production System. In some areas its Production System. In some areas its philosophy seem exactly opposite to the philosophy seem exactly opposite to the fundamental principles of Mass Production fundamental principles of Mass Production System.System.This system is generally known as JIT This system is generally known as JIT system, which in fact is an important pillar system, which in fact is an important pillar of Lean Production System.of Lean Production System.The slogan of Lean Production is “Less is The slogan of Lean Production is “Less is best”best”




Just-in-Time• Leveled Production

• Pull System

• Continuous Flow Processing

• Takt Time

• Flexible Work Force

• 3 Ms

• 5 S

Standardized Work Kaizen (Continuous Improvement)

Jidoka (Automation)

• Andon-Fixed Position Stop System• Pokayoke- Fail Proofing

System

Just-in-Time (JIT) SystemJust-in-Time (JIT) System

Just-in-Time means PRODUCING:Just-in-Time means PRODUCING:

a) Only what is neededa) Only what is needed

b) in necessary quantityb) in necessary quantity

c) at necessary c) at necessary timetime


Main Components of JITMain Components of JIT Leveled ProductionLeveled Production

Pull SystemPull System

Continuous Flow ProcessingContinuous Flow Processing

Takt TimeTakt Time

Flexible Workforce (Shojinka)Flexible Workforce (Shojinka)

3 Ms3 Ms

5 S5 S


Leveled Production means producing Leveled Production means producing various model variations on the same line various model variations on the same line to cater the customer demandto cater the customer demand


Conveyer Belt

Leveled Production-Flexible Production LineLeveled Production-Flexible Production Line


Pull System (Don’t Push)Pull System (Don’t Push)

Produce only when your customer Produce only when your customer demands the product in the required demands the product in the required quantity.quantity.

Run the production according to this Run the production according to this demanddemand


Pull System or Kanban System?Pull System or Kanban System?


Continuous Flow ProductionContinuous Flow Production

In TPS it means arranging work inside In TPS it means arranging work inside each process to flow smoothly from one each process to flow smoothly from one step to otherstep to other



Process A

Process C

Process B

Just-in-Case (JIC) Involves the use of buffer or safety stock

Buffer or

Safety Stock

Buffer or

Safety Stock


Process A

Process C

Process B


Process A

Process C

Process B

Defect detected at Process B that

actually occurred at Process A


Process A Process B Process C

Smooth Flow Processing


Process A Process B Process C

Smooth Flow Processing

Defect is detected and countermeasures

are taken immediately

Takt TimeTakt Time: Takt is a German word meaning “meter”. : Takt is a German word meaning “meter”. It is the time to finish a given amount of work-doing a single It is the time to finish a given amount of work-doing a single

operation, making one component, or assembling an entire car.operation, making one component, or assembling an entire car.


Takt time =Total daily operating time

Total production requirement

Takt time = 480

100= 4.8 min/ vehicle

Flexible Workforce (Shojinka)Flexible Workforce (Shojinka) Flexible workforce or shojinka means to Flexible workforce or shojinka means to

alter (decrease or increase) the number of alter (decrease or increase) the number of operators within a shop, to equip with operators within a shop, to equip with demand changes.demand changes.


Multi-machine HandlingMulti-machine Handling


Type of Part

A B C D

Machine (Lathing) 1

Machine (Milling) 2 Machine (Drilling) 3

Machine (Tapping) 4

One person handles one process, four machines

Unfinished Parts

Finished Products

Multi-process HandlingMulti-process Handling


Type of Part

A B C D

Machine (Lathing) 1

Machine (Milling) 2 Machine (Drilling) 3

Machine (Tapping) 4

One person handles four processes, four machines

3 3 MM’s’s MMUDA = Non-Value AddedUDA = Non-Value Added

MMURA = OverburdenURA = Overburden

MMURI = Unevenness URI = Unevenness



1 TON

4 ton

Capacity : 4 tons

Muda . Mura . Muri

12 TONS


X

X

2 =

MURI (OVERBURDEN)

6 =

MUDA (NON-VALUE ADDED)

= MURA (UNEVENNESS)

The most efficient way to deliver 12 tons of good to the destination is:The most efficient way to deliver 12 tons of good to the destination is:


X 3 =

NO MURI (OVERBURDEN)

NO MUDA (NO WASTAGE)

NO MURA (NO UNEVENNESS)


5S1. SEIRI = SIFTING2. SEITON = SORTING3. SEISO = SWEEPING4. SEIKETSU = SPICK ‘N’ SPAN5. SHITSUKE = SUSTAINANCE

SEIRI = SIFTINGSEIRI = SIFTING

Get rid off unwanted stuff from the workplaceGet rid off unwanted stuff from the workplace


TRASH

Unwanted

SEIRI = SIFTINGSEIRI = SIFTING


SIETON = SORTINGSIETON = SORTING

Arranging wanted items in proper order, which means place for Arranging wanted items in proper order, which means place for every thing and every thing in its place.every thing and every thing in its place.


Boxes staked well sorted and orderly manner

Disorderly staking

SIETON = SORTINGSIETON = SORTING


SIESO = SWEEPING AND CLEANINGSIESO = SWEEPING AND CLEANING

Sweeping and cleaning means surface and other areas free from oil Sweeping and cleaning means surface and other areas free from oil and chemicals that may or may not cause slippage, fire or any and chemicals that may or may not cause slippage, fire or any other possible hazard.other possible hazard.


SEIKETSU = SPICK ‘N’ SPANSEIKETSU = SPICK ‘N’ SPAN


Spick ‘n’ span means visible neatness. A nice, clean and tidy workplaceAffects directly to the performance and quality of workforce.

SEIKETSU = SPICK ‘N’ SPANSEIKETSU = SPICK ‘N’ SPAN


SHITSUKE = SUSTAINANCESHITSUKE = SUSTAINANCE Instilling supreme attitude and constantly reminding the Instilling supreme attitude and constantly reminding the

workforce about 5 S philosophy through training, competition, workforce about 5 S philosophy through training, competition, encouragement by the top management.encouragement by the top management.


Benefits of JITBenefits of JIT Reduction of direct and direct labor by eliminating non-value added Reduction of direct and direct labor by eliminating non-value added

activitiesactivities Reduction of floor space and warehouse space per unit of outputReduction of floor space and warehouse space per unit of output Reduction of setup time and schedule delays as the factory Reduction of setup time and schedule delays as the factory

becomes a continuous production process.becomes a continuous production process. Reduction is waste, rejects, and rework by detecting errors at the Reduction is waste, rejects, and rework by detecting errors at the

source.source. Reduction of lead time due to small lot sizes, so that downstream Reduction of lead time due to small lot sizes, so that downstream

work centers provide feedback on quality problems.work centers provide feedback on quality problems. Better utilization of machines and facilities.Better utilization of machines and facilities. Better relations with suppliers.Better relations with suppliers. Better integration of and communication between functions such as Better integration of and communication between functions such as

marketing, purchasing, design, and production.marketing, purchasing, design, and production. Quality control built into the process.Quality control built into the process.


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