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History of Lean Production

This document provides a brief history of the Toyota Production System (TPS) and Lean manufacturing. It outlines the origins of Toyota Motor Corporation and the drivers for developing TPS. The core elements of TPS are described, including eliminating waste, minimizing batch sizes, standardizing processes, and taking a holistic supply chain perspective. Key contributors to developing TPS like Taiichi Ohno and Shigeo Shingo are also mentioned.

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Marco Rivera
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114 views

History of Lean Production

This document provides a brief history of the Toyota Production System (TPS) and Lean manufacturing. It outlines the origins of Toyota Motor Corporation and the drivers for developing TPS. The core elements of TPS are described, including eliminating waste, minimizing batch sizes, standardizing processes, and taking a holistic supply chain perspective. Key contributors to developing TPS like Taiichi Ohno and Shigeo Shingo are also mentioned.

Uploaded by

Marco Rivera
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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TUM School of Management

Production and Supply Chain Management


Prof Martin Grunow Technische Universität München

Brief History of Lean Production:


The Toyota Production System

Professor Holly Ott


Production and Supply Chain Management
Chair: Prof. Martin Grunow
TUM School of Management

Holly Ott 1
TUM School of Management
Production and Supply Chain Management
Prof Martin Grunow Technische Universität München

Learning Objectives
• Outline the history of the Toyota Motor Corporation from the
Toyoda Automatic Loom Works.
• Describe the historical drivers for the development of the Toyota
Production System at Toyota and identify the important
contributors to TPS.
• List the core elements of the Toyota Production System.

Holly Ott 2
TUM School of Management
Production and Supply Chain Management
Prof Martin Grunow Technische Universität München

Brief History of TPS


• 1926 Sakichi Toyoda: Toyoda
Automatic Loom Works
• 1933 Kiichiro Toyoda: automotive
division. Produced military trucks
during WWII

©2012 from "A First Course in Quality Engineering: Integrating


Statistical and Management Methods of Quality" by K.S.
Krishnamoorthi. Reproduced by permission of Taylor and Francis
Group, LLC, a division of Informa plc.

Holly Ott 3
TUM School of Management
Production and Supply Chain Management
Prof Martin Grunow Technische Universität München

Brief History of TPS


• 1926 Sakichi Toyoda: Toyoda
Automatic Loom Works
• 1933 Kiichiro Toyoda: automotive
division. Produced military trucks
during WWII
• After war, shortages, little cash…
Ford Motor Co. at the Rouge plant
near Detroit producing 7,000
cars/day. Toyota producing 200 per
year
• 1940s Eiji Toyoda … needed to do ©2012 from "A First Course in Quality Engineering: Integrating
Statistical and Management Methods of Quality" by K.S.
things differently! Krishnamoorthi. Reproduced by permission of Taylor and Francis
Group, LLC, a division of Informa plc.

Holly Ott 4
TUM School of Management
Production and Supply Chain Management
Prof Martin Grunow Technische Universität München

Brief History of TPS


• Toyota Production System – Lean
Manufacturing
• Taiichi Ohno is credited for creating the
the system
• Dr. Shigeo Shingo, author Single Minute
Exchange of Die procedure.
https://en.wikipedia.org/wiki/Taiichi_Oh
• Quantity Control (Just In Time) no#/media/File:Taiichi_Ohno.jpeg

• Quality Control & Improvement


• Waste and Cost Control
• The term “Lean” is from John Krafcik’s
1988 article “Triumph of Lean
Production Systems.”
Holly Ott 5
TUM School of Management
Production and Supply Chain Management
Prof Martin Grunow Technische Universität München

Source: K. Mishina (1992)


Core Elements of TPS
• Maximize share of value-adding • Create a self-learning, continuously
activities improving organization
- Elimination of “waste” (muda) - Create transparency on problems/
- Strive to minimize batch sizes (ideally facilitate immediate identification
single piece flow) - Conduct rigorous root-cause problem
- Build processes based on true customer solving
requirements - Make continuous improvement part of the
daily work
• Implement stable, standardized
• Take a holistic Supply Chain
processes
perspective
- Workplace organization
- Standard Operating Procedures - Customer requirements - driven
- Fail-safe processes (Jidoka) perspective
- Backwards integration to include suppliers
• People development is the key
Reference: TUM School of
Management, Chair: Production success factor
and Supply Chain Management,
Course: Introduction to Lean
- Employee skill building is an important
Production part of the TPS
Holly Ott 6
TUM School of Management
Production and Supply Chain Management
Prof Martin Grunow Technische Universität München

Brief History of Lean Production:


The Toyota Production System

Professor Holly Ott


Production and Supply Chain Management
Chair: Prof. Martin Grunow
TUM School of Management

Holly Ott 7

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