Lean Manufacturing Lec 1

LEAN
MANUFACTURING
ISYE 352 - Spring 2022
Lecture 1
Saed T. Amer
Saed.amer@ku.ac.ae
Check in
■ Attendance check
Contents
■ Introduction
■ What is the Toyota production system (TPS)?
■ History of the Toyota Production System
■ Goals of the Toyota Production System
Definition
■ Lean Manufacturing – A way to eliminate waste and improve
efficiency in a manufacturing environment
■ Lean focuses on flow, the value stream and eliminating muda,
the Japanese word for waste
■ Lean manufacturing is the production of goods using less of
everything compared to traditional mass production: less waste,
human effort, manufacturing space, investment in tools,
inventory, and engineering time to develop a new product
■ Is a pursuit of perfection via systematic approach to identifying
and eliminating waste (non-value-added activities) through
continuous improvement by flowing the product at the pull of
the customer.
Conventional Manufacturing
■ In conventional production systems, parts produced by one process, as defined by the
production schedule, are delivered to following processes even if they are not yet
needed there.
■ Parts are released according to the production schedule depending solely on the
available capacity in downstream process.
■ Once released, the parts flow from one process to the other through the production
system regardless of what happens downstream. Hence the term “push” is used for this
method; parts are pushed through the production system.
■ This method may be good when parts can be produced on schedule throughout the
whole process. But if just one process has trouble and the line stops, the processes
directly related to the troubled one will suffer from either a shortage or a backup of
parts. This is called a “push” system.
■ To avoid the accumulation of the work in process (WIP) between the production
processes and the build up of finished products inventory, a different production
planning strategy was introduced in the late 1960s by Toyota Motors Company in Japan.
Toyota production system (TPS)
■ TPS is a system for the absolute elimination of waste, and the way it accomplishes this
is by producing only what’s needed, when it’s needed and in the quantity it’s needed.
■ The Toyota production system is 80 percent waste elimination, 15 percent production
system and only 5 percent kanban.
■ Some people imagine that Toyota has put on a smart new set of clothes, the kanban
system, so they go out and purchase the same outfit and try it on. They quickly discover
that they are much too fat to wear it! They must eliminate waste and make fundamental
improvements before techniques like kanban can be of any help.
■ It took Toyota Motors twenty years to develop the Toyota production system fully, and
others will require a minimum of 10 years to obtain satisfactory results by copying it.
History
History of the (TPS)
■ The Toyota Production System (TPS) arose out of necessity in response to the
circumstances surrounding the company.
■ The company was quite poor and could not afford to waste money on excess equipment or
materials in production. Everything was expected to be procured just in time and not too
early or too late.
■ The most famous element of the TPS is no doubt the Just-in-Time pillar of the production
system. The phrase Just-in-Time was coined by Kiichiro Toyota in 1937 after the start of
Toyota Motor Corporation.
■ The oldest part of the production system is the concept of Jidoka which was created in 1902
by Toyoda founder Sakichi Toyoda. This concept pertains to notion of building in quality at
the production process as well as enabling separation of man and machine for multi-process
handling.
■ Later elements developed in the 1950’s including takt time, standardized work, kanban, and
supermarkets added to the basis for JIT.
■ There are also many other tools and techniques that were developed in Toyota such as 7
Wastes, 5S, SMED, Visual Control, Error Proofing, as well as many others. The concepts
will be explained in the latter sections of this chapter.
Goals of the Toyota Production System
1. Provide world class quality and service to the

customer.
2. Develop each employee’s potential, based on
mutual respect, trust and cooperation.
3. Reduce cost through the elimination of waste
and maximize profit
4. Develop flexible production standards based
on market demand.
The Toyota Production System Model
Just In Time (JIT)
■ The JIT concepts aim to produce and deliver the right
parts, in the right amount, at the right time using the
minimum necessary resources.
■ This system reduces inventory, and strives to prevent
overproduction (producing more, sooner or faster than is
required by the next process).
■ Producing in a JIT fashion exposes problems quickly.
Jidoka (Build in quality)
■ Jidoka is a Japanese word that ordinarily means automatic or automation.
■ Building in quality at the process: TPS aspires for processes that are
capable of making intelligent decisions and shutting down automatically
at the first sign of an abnormal condition such as a defect, or other
problem.
■ The goal is not to run continuously but to stop running automatically
when trouble arises.
■ Enabling separation of man from machine in work environments: When
machines possess the ability to stop in the event of a problem then there
is no need for humans to stand and watch the machine.
■ Jidoka frees people being tied to machines and monitoring them and puts
people to use in a more value added fashion.
Check out
■ Any questions?.

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1. Provide world class quality and service to the

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