History of Lean Agile Tour Ho Chi Minh 2012 Kiro HARADA
原田 騎郎 Kiro HARADA Agile Coach Domain Modeler SCM Consultant
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 Paper “Triumph of Lean Production System” – Study on Toyota Production System International Motor Vehicle Program(IMVP) at MIT Sloan School 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)
Toyoda Type G Automatic Loom (1924) 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
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 MuriOverload / Overburden ↓ ムラ MuraUnevenness ↓ ムダ MudaWaste 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 People When do you have a strong motivation for work? Survey in Japanese and U.S. automakers showed the same result. 1.Autonomy 2.Responsibility 3.Achievement 4.Opportunity 5.The work itself 6.Advancement 7.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