搜索
ToyotaKaizenPatterns&BasicStability:SomeobservationsandreflectionsonTPS©ArtofLean,Inc.ArtSmalleyPresidentArtofLean,Inc.PresentationOutline•Introduction•TheNeedforBasicStability•TPSDevelopmentTimeline•PatternsofTPS/KaizenCopyright©2005ArtofLean,Inc.©ArtofLean,Inc.•ScientificMethod•Suggestions•FinalQ&ATheNeedForBasicStabilityProcessProcessProcessCustomerAvailability100%Quality100%Availability70%Quality93.5%Copyright©2005ArtofLean,Inc.©ArtofLean,Inc.Ideal!C/OFlexibility100%Ofcourseanidealprocesswouldhavenoproblemsbutwhohasthatsituationintheirfacility?Reality…C/OTime=1hourTPSdevelopmenttimeline19372009InfluencesMassProductionmovingconveyorlinesScientificPrinciplesOfManagementStandardizationTPSDevelopment195019731902LoomsAutomotiveCompanyCopyright©2005ArtofLean,Inc.©ArtofLean,Inc.Guesswhat–itdidnotjusthappenovernight!StandardizationOfPartsSakichiToyodaKiichiroToyodaEijiToyodaTaiichiOhnoFujioChoTPSSummary*1945-1965JIT1.Processflow2.Conveyance3.SetupReduction4.Kanban5.PurchasePartsManagementTopic/Dates1945-551955-65’6215MinuteAverageC/O(NewTechnology–DanlyStampingPresses)’501-4HourSetUpTime’50MachineShopFlow’50MachiningandAssemblyLineFlow’55EnginetoVehiclePlantFlow’60IntraPlantFlow’531-4MaterialHandlingCallSystem’55Fixedquantityunfixedtimebasedsystem’60IntraPlantTimeDelivery’48Replenishmentpullpilot’53Machineshopsimplementpull&levelscheduling’62Companywidepullestablished’55Fixedquantitydeliverycontrolsystem’65AdoptionofsupplierkanbanCopyright©2005ArtofLean,Inc.©ArtofLean,Inc.Jidoka6.OrderingSystem7.ProductionInstruction8.Multi-ProcessHandling&StandardizedWork9.VisualControl&InProcessControl*Source:創造限りなくトヨタ自動車５０年史.Toyota50YearHistoryPublished1987’471Man2Machines’491Man4Machines’53StandardizedWork’50Andonlightsonengineassemblyline’62Fullworkcontrolsystem/Pokayoke’65Adoptionofsupplierkanban’57AdoptionofSequenceList’63JITProductionInstructionSignals’55MonthlyProductionPlans’551Man7Machines(averageinmachineshop)TPSSummary*1965-1985JIT1.Processflow2.Conveyance3.SetupReduction4.Kanban5.PurchasePartsManagementTopic/Dates1965-751975-85’713MinuteAverageC/OPressMachines’77BarCodeReaderforSupplierKanban’75SingleMinuteC/OMachinesatSuppliers’75SynchronizationofFlowBetweenPlants’75DevelopmentofEquipmentforFlowProduction’70AllPlantsonCallConveyanceMethod’83ReviewfromSalestoManufacturing’77CrossDockingMethods’77KanbanAutoSortingandReadingCopyright©2005ArtofLean,Inc.©ArtofLean,Inc.Jidoka6.OrderingSystem7.ProductionInstruction8.Multi-ProcessHandling&StandardizedWork9.VisualControl&InProcessControl*Source:創造限りなくトヨタ自動車５０年史.Toyota50YearHistoryPublished1987’75CompanyWideStandardizedWork’6510DayOrderEntrySystem’70DailyOrderEntrySystem’74NewOrderSystem’85LeadTimeReductionProject’66FullAutomatedMachiningLines(JIT&JidokaFulfilledKamigoModelPlant)’71DevelopmentPlantProductionInstructionSignals’80AdoptionofAutomaticSignals’86NewTechnologySystemFirstTPSManual19731.TPSisaseriesofrelatedactivitiesaimedateliminationofwasteinordertoreducecost,improvequality,andimproveproductivity.“Practiceovertheory”ManagingDirectorOhnoTaiichiCopyright©2005ArtofLean,Inc.©ArtofLean,Inc.FirstTPSManual.1973Education&TrainingDepartmentimprovequality,andimproveproductivity.2.ScientificMindset:Ontheshopflooritisimportanttostartwithactualphenomenonandsearchfortherootcauseinordertosolvetheproblem.Inotherwordswemustemphasizegettingthefacts..3.Inproblemsolvingthepurposemustbemadeclear…inKaizentheneedsmustbemadeclear.SampleearlytrainingcoursesinToyota(1950’sforward)•TrainingWithinIndustry(TWI)Courses-Startedin1951&itsinfluencecontinuestoday1.JobInstruction2.JobRelations3.JobMethods--Replacedin1955bytheP-coursetraining4.JobSafety--InternalversionaddedbyToyotatotheabovecourses•Various“P-Courses”taughtbyMr.Shingo–Startedin1955andcontinueduntil1980taughtonaverage3timesperyearmainlyon:1.Motionanalysis2.Timestudyanalysis3.OperationalanalysisCopyright©2005ArtofLean,Inc.©ArtofLean,Inc.3.Operationalanalysis4.Processanalysis•TQCrelatedcourses(Startingaround1962withtheTQCprogram)1.QCCircleactivity2.Basicproblemsolving3.Statisticalqualitycontrol•Standardizedwork–establishedintheearly1950’sandrefinedupuntil1978•Kaizentrainingcourse–formalizedin1978andreplacedtheP-course•RoleofaSupervisor–formalizedin1970andcontinuestoday1.RoleofaTeamLeader2.RoleofaGroupLeaderTPSKaizenPatterns(e.g.“Method”)•Threemaintypes(andmanyderivatives…)1.Man2.Material3.MachineMethodCopyright©2005ArtofLean,Inc.©ArtofLean,Inc.GenericAutomotivePlantVehiclePlantEngines-Casting-Forging-Machining-AssemblyTransmissionChassisStampingBodyWeldPaintPlasticInjectionFinalAssemblyLineComponentsCopyright©2005ArtofLean,Inc.©ArtofLean,Inc.RelativelyMachineIntensiveRelativelyPeople&MaterialIntensivePartsSuppliersMillsLathesGearCutterGrinderWIPWIPWIPProcessBasedLayoutInOhno’sMachineShopsWIPWIPWIPCopyright©2005ArtofLean,Inc.©ArtofLean,Inc.•BuildupofWIPbetweenstationsanddepartments•Over-productionofwrongitems/under-productionofneededitems•Specializedoperatorsonlyranonetypeofmachine•Hardtorealizeproductivitygains/workun-balanced•Defects