Business Processes:

Lean Production

Lean Manufacturing Doing More With Less

7 Principles of Toyota Production System (TPS)

 

 

Just-in-Time (JIT) Seven Wastes Lean Manufacturing (or Lean Production) Toyota Production System (case study) Continuous Improvement Firm (CIF) Case Studies Toyota Production System (TPS) - Lean Manufacturing / Lean Production

 

The Toyota Way: 14 Principles

 

 

 

Lean Enterprise: 13 Tips

 

Lean Production

The Toyota Way: 14 Principles

5 Elements of Enabling a Lean Approach

13 Tips for Transitioning Your Company To a Lean Enterprise

5S

10 Commandments of Improvement

TPS-Lean Six Sigma Linking Human Capital to Lean Six Sigma

Kaizen

Quick and Easy Kaizen

Kaizen Mindset

Successful Implementation of Kaizen Strategy: 7 Conditions

Kaizen vs Kaikaku and 10 Kaikaku Commandments

Glossary Kaizen & Lean Production

Case Studies

Toyota Production System (TPS)

Canon Production System (CPS)

Gold Seal Engineering Ltd. (India)

Rojee Tasha Stamping Ltd. (India)

Thara Engineering (India)

Three Small- and Medium-sized Firms (USA)

Continuous Improvement Firm (CIF)

Efficiency Improvement

Productivity Improvement

Japanese-style Suggestion System

9 Waste Categories and 6 Guidelines of the Canon's Suggestion System

Five Ss at Canon

 
  1. Reduced Setup Times:

    All setup practices are wasteful because they add no value and they tie up labor and equipment. By organizing procedures,  using carts, and training workers to do their own setups, Toyota managed to slash setup times from months to hours and sometimes even minutes.

  2. Small-Lot Production: Producing things in large batches results in huge setup costs, high capital cost of high-speed dedicated machinery, larger inventories, extended lead times, and  larger defect costs. Because Toyota has found the way to make setups short and inexpensive, it became possible for them to economically produce a variety of things in small quantities. 

  3. Employee Involvement and Empowerment:

    Toyota organized their workers by forming teams and gave them the responsibility and training to do many specialized tasks. Teams are also given responsibility for housekeeping and minor equipment repair. Each team has a leader who also works as one of them on the line.

  4. Tao of Employee Empowerment

  5. Quality at the Source: To eliminate product defects, they must be discovered and corrected as soon as possible.  Since workers are at the best position to discover a defect and to immediately fix it, they are assigned this responsibility. If a defect cannot be readily fixed, any worker can halt the entire line by pulling a cord (called Jidoka).

  6. Equipment Maintenance: Toyota operators are assigned primary responsibility for basic maintenance since they are in the best position to defect signs of malfunctions. Maintenance specialists diagnose and fix only complex problems, improve the performance of equipment, and train workers in maintenance.

  7. Pull Production:

    To reduce inventory holding costs and lead times, Toyota developed the pull production method wherein the quantity of work performed at each stage of the process is dictated solely by demand for materials from the immediate next stage. The Kamban scheme coordinates the flow of small containers of materials between stages. This is where the term Just-in-Time (JIT) originated.

  8.  
  9. Supplier Involvement: Toyota treats its suppliers as partners, as integral elements of Toyota Production System (TPS). Suppliers are trained in ways to reduce setup times, inventories, defects, machine breakdowns etc., and take responsibility to deliver their best possible parts.

The 7 Wastes To Be Eliminated

Overproduction; Waiting, Transportation; Inventory; Motion; Over-processing; Defective Units.

Just-In-Time (JIT)

In Kaizen, JIT is a is a collection of concepts and techniques for improving productivity. JIT is a process aimed at increasing value-added and eliminating waste by providing the environment to perfect and simplify the processes... More

Kaizen Mindset

Five Ss

The Five Ss refer to the five dimensions of of workplace optimization: Seiri (Sort), Seiton (Set in order), Seiso (Shine), Seiketsu (Standardize), and Shitsuke (Sustain)... More

 

Free Micro-course

10 slides

Kaizen

 

 

 

References:

  1. Toyota Production System, Taiichi Ohno

  2. The Toyota Way, Jeffrey Liker

  3. Kanban Just-In-Time at Toyota, Japan Management Association

  4. Lean Manufacturing Overview, 42 PowerPoint slides by Factory Strategies Group LLC

  5. Lean Manufacturing That Works, Bill Carreira

  6. Lean Production Simplified, Pascal Dennis, John Shook

  7. The Lean Manufacturing Pocket Handbook, Kenneth W. Dailey

  8. A Team Leader's Guide to Lean Kaizen, William Wes Waldo and Tom Jones

  9. Kaizen, 25 PowerPoint slides by Factory Strategies Group LLC

  10. Synergizing Value Chain, Vadim Kotelnikov

  11. Synergizing Business Processes, Vadim Kotelnikov

  12. Continuous Improvement Firm (CIF), Vadim Kotelnikov

Kaizen Culture: 8 Key Elements

Areas Targeted by TQM in Japan