GROUP 1

SUEZ CANAL UNIVERSITY

FACULTY OF ENGINEERING
• Maximising productivity while simultaneously.
Minimising waste within a manufacturing operation.

• Reduced lead times and operating costs and improved

product quality.

• Waste is anything that doesn’t add value that the customers are
willing to pay for.
 Transport Inventory Overprocessing

Overproduction Motion Waiting Defects

 the production was hand-crafted

During Industrial revolutions

Until today, the industrial environment
has known four major revolutions
Eli Whitney Adam Smith
the cotton gin “division of labor”
transformation and the when a large job is divided
concept of into small tasks and each
“interchangeable parts” task is assigned to one
worker.
Frederick Taylor Frank Bunker Gilbreth
His ideas focused on The Shape of Motion Study and
individual workers and their Human Factors.
methods of performing work at This originated the doctrine of
the factory level. JIT and Lean Manufacturing
brought up concepts of
Standardized Work, Time
Study, and Work Standards
 THE GREAT THINKERS IN
THE HISTORY OF LEAN

Henry Ford Sakichi Toyoda Taiichi Ohno James Womack

He initiated the concept Established Toyoda work on excess inventory Integrated the concepts
of Manufacturing Automation Loom Works. It of both work-in-progress of the past and future
Strategy; in which on was the best example of and finished goods one of manufacturing processes
the pioneers of the lean in the shape of the book-
the manufacturing site the principle of Jidoka
manufacturing, was the “The Machine That
they used all the
first to identify seven Changed The World”
resources of the
types of waste
manufacturing system
Cellular Manufacturing
Cellular Manufacturing
Cellular Manufacturing

Chemical
milling Deburring
tre.

Painting Boring

Assembly
Group Technology
Production Flow Analysis

1 2

3
Production Flow Analysis

1 2

3 4
01

02
01

02

03
 Objectives Just-in-Time

Reduce Wastage Increment in Production

Efficiency

Improve Quality Minimize Lead and

Set-up time
 Add your Add your Add your
main point main point main point
here here here

Add your
main point
here

Add your Add your

main point main point
here here
01 Visualize the Work
03 Focus and Flow

02 Limit the Work in

Progress (WIP) 04 Continuous
Improvement
 Better Improved Increased
visibility efficiency Reduced waste
productivity
バリューストリームマッピング
What Is VSM ?
01 02 03 04 05
 Healthcare Service
industry

Manufacturing

Software
development
 01 05

02 04

03
4
01

03

02
04
 5S
Sort 1 Set in order 2 Shine 3

Standardize 4 Sustain 5
1
2
 TOYOTA
case study
Diversification:
Toyota Motor Corporation, transitioning towards automobile manufacturing.

War Period:
producing military vehicles and trucks during wartime.
Transition Period:
resource scarcity and reconstruction challenges.
Jidoka Implementation
Jidoka concept, automated loom machines
JIT Concept Emergence
minimize waste
Taiichi Ohno's Contributions
Quick die Exchange
TPS Foundation
Jidoka and JIT principles

KAIZEN Integration
Continuous Improvement
Global Expansion and Advancement (1980s-2000s):
TPS Maturing
emphasizing the elimination of waste, efficient supply chain management

Toyota Way Philosophy

stressing leadership behaviors, continuous improvement
Global Expansion and Advancement
(1980s-2000s)
Modern Era (2010s-Present)
Continuous Evolution
emphasizing the elimination of waste, efficient supply chain
management
Adaptation to Challenges
stressing leadership behaviors, continuous
improvement
Development of Lean Manufacturing (1950s-1960s) & TPS Creation (1950s-1970s)

Global Expansion & Advancement (1980s-2000s)

 •
• •
• •
• •
• •
NUMMI
This plant opened in 1963
HISTORY
HISTORY
START
 JOINT VENTURE
1 2 3

4 5
 TOYOTA STEPS

1 2
 TOYOTA STEPS

3 4
ANNULA PRODUCTION
END
ありがとうございました