Hochschule für Technik und Wirtschaft des Saarlandes -
University of Applied Sciences
LEAN MANAGEMENT
Prof. Dr. Udo Venitz
Lean Management
Contents
Fundamentals
• Origin and History of Lean Management
• The Toyota Production System
• Targets of a Lean System
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Origin an History of Lean Management
Lean Management is derived mostly from the Toyota Production System.
Production System
(TPS)
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The Toyota Production System (TPS)
The TPS is build on the two pillars Just-In-Time and Jidoka.
Source: [Link]
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The Toyota Production System (TPS)
„Quality must be built in during the manufacturing process!“ (Toyoda Sakichi)
Jidoka = Autonomation = Automation with a human touch
Toyoda Sakichi (1876 ~ 1930)
Type-G Toyoda Automatic Loom
(developed in 1924)
1929 Kiichiro Toyoda sold the Patent in England
1930 Toyota Motor Corporation founded
Source: [Link]/en/
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Targets of a Lean System
The main target of every company is to generate Profit.
Profit
Satisfy customer demand
Best Prices Supply on time
Costs
Lowest Costs Shortest Lead Time Best Quality
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Contents
Fundamentals
• Origin and History of Lean Management
• The Toyota Production System
• Targets of a Lean System
Basic Elements Wheel of
Improvement
• Muda – 7 types of waste
• KAIZEN – CIP
• Standards
• Visual Management
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Basic Elements - MUDA
Wastes in all our processes lead to higher costs and longer lead times.
Muda – the 7 types of waste
Inventory
Overproduction Transport
Correction/ Scrap
(Over-)Processing
Motion
Waiting
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Basic Elements - KAIZEN
We are continuously eliminating wastes by KAIZEN.
KAIZEN = Continuous Improvement (CIP)
CI P
Wheel of
Improvement
improvement
KAI = „change“
Standard
time
ZEN = „for the better“
Source: KAIZEN-Institute
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Basic Element - Standards
“Without standards there can be no improvement” (Taiichi Ohno)
CIP
Wheel of
Improvement
improvement
Standard
time
Source: KAIZEN-Institute
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Basic Elements – Standards
Standards should be used everywhere in our work environment!
Source: ixetic GmbH
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Basic Elements – Visual Management
Visual management is an important method
for a shop floor manager
to manage the daily business easily
Visual management shows any difference
between normal and abnormal
production processes
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Basic Elements – Visual Management
Easy means can show us important informations!
Traffic Light Systems Machine Conditions
Source: KAIZEN-Institute
Source: ixetic GmbH
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Contents
Fundamentals
Basic Elements
Just-In-Time (JIT)
• Flow
• One-Piece-Flow
• Pull-System
• Kanban
• Supermarkets
• Heijunka - Production Leveling
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Just-In-Time (JIT)
„Making only what is needed, when it is needed, and in the amount needed!"
Ohno Taiichi (1912 ~ 1990)
o rd e r T im e lin e cash
Waste
Overproduction Inventory Value Added
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Just-In-Time – Flow
Job-Shop Production is often full of waste, since there is no flow.
Overproduction
Job-Shop Production
Inventory
Transport Waiting
Motion
(Over-)Processing
Correction/ Scrap
Source: Liker Jeffrey K.: The Toyota Way, McGraw-Hill, New York 2004
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Just-In-Time – One Piece Flow
Wherever possible establish a One Piece Flow.
Overproduction
Flow in a U-Shaped Production Line Inventory
Transport
Waiting
Motion
(Over-)Processing
Correction/ Scrap
Source: Liker Jeffrey K.: The Toyota Way, McGraw-Hill, New York 2004
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Just-In-Time – Pull Principle
When it is not possible to let the material flow pull the material!
Synchronized Production
One Piece Flow / Continuous Flow Pull - Principle
Source: Syncro Consult GmbH & Co. KG Source: Syncro Consult GmbH & Co. KG
Inventory in the production
Closed Loop
Source: Eidenmüller
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Just-In-Time – Kanban
The Kanban System is a easy mean to control the material flow.
Kanban System
Source: [Link]
Source: [Link] Source: [Link]
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Just-In-Time – Kanban
The parts retrieval kanban controls quantity and transport of the finished parts.
parts retrieval kanban
Varnishing Mounting
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Just-In-Time – Supermarket
The previous process can be seen as a Supermarket.
Source: ixetic GmbH
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Just-In-Time – Supermarket
Supermarkets assure a supply of the next process!
Supermarket
Supplier Customer
• defined place with minimum, maximum and reorder level
• high visualization of inventory
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Just-In-Time – Production Leveling
Variable customer demand makes a utilisation of Supermarkets difficult.
Source: Syncro Consult GmbH & Co. KG
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Just-In-Time – Production Leveling
By batch production we try to reduce the frequency of change over.
Batch Production
Thursday D Change
Over
Wednesday C Change
Over
Tuesday B Change
Over
Monday A Change
Over
8:00 10:00 12:00 14:00 16:00 17:00
Total Number of Change Over Procedures: 4
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Just-In-Time – Production Leveling
The target of production leveling: Every Part every Day!
Heijunka = Production Leveling
Thursday A B C I JK
Wednesday A B C D H
Tuesday A B C F G
Monday A B C D E
8:00 10:00 12:00 14:00 16:00 17:00
Total Number of Change Over Procedures: 21
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Summary
We need all the methods to build up a lean system!
Just-In-Time (JIT)
• Flow
• One-Piece-Flow Highest Quality, Lowest Cost, Shortest Lead Time
• Push-System
• Pull-System
• Kanban JIT Jidoka
• Supermarkets
• Production Leveling
Donnerstag A B C I JK Basic Elements
Mittwoch A B C D H
Dienstag A B C F G
Montag A B C D E
8:00 10:00 12:00 14:00 16:00 17:00
Basics Elements Overproduction
• Muda – 7 types of waste Wheel of
CIP
Improvement
• KAIZEN – CIP
improvement
• Standards Standard
• Visual Management time
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