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Introduction to Lean Methodology

Lean Methodology history and concept

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Win Pyae Pyae
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23 views

Introduction to Lean Methodology

Lean Methodology history and concept

Uploaded by

Win Pyae Pyae
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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Fundamentals of Lean Principles

and Concepts

1
Introduction to Lean Methodology
Introduction to Lean Methodology
• Lean methodology focuses on delivering value to the customer
while minimizing waste.
• Lean is fundamentally a mindset that emphasizes continuous
improvement in all aspects of processes, products, and services,
rather than just a collection of tools or techniques.

Origins of Lean Methodology


• The principles of lean have been present in various
forms throughout history, but they gained significant
attention in the mid-20th century through the Toyota
Production System (TPS) in Japan.
• Developed under the leadership of Taiichi Ohno and
Eiji Toyoda, TPS aimed to eliminate wasteful practices
and enhance overall efficiency.

3
Key Objectives of Lean Methodology

• Customer Focus: Identify what the customer values and


adjust processes to deliver that value efficiently.
• Eliminate Waste: Identify and remove activities or resources
that do not add value to the process.
• Continuous Improvement (Kaizen): Constantly seek
opportunities to enhance processes, no matter how minor
the improvements may seem.
• Respect for People: Recognize that employees are essential
for improvement. Empower them to identify problems and
propose changes.
4
Difference between Traditional and Lean Thinking
• Traditional manufacturing focuses on mass production,
economies of scale, and inventory management.
• Lean thinking emphasizes flow, pull systems, and the human
element.
• The primary objective of traditional manufacturing is production
efficiency, while lean aims for value creation with minimal waste.

Lean Thinking in Today's World


• Lean thinking has expanded beyond its roots in the automotive industry.
• It now benefits sectors like healthcare, IT, construction, and services.
• With digitalization, lean principles are applied in digital product
development and software delivery.
• Lean is a mindset focused on prioritizing value and eliminating waste to
streamline processes, enhance products and services, and boost customer
satisfaction. 5
Historical Evolution of Lean Manufacturing
• Lean manufacturing has evolved over time, combining ideas and
practices aimed at improving efficiency and reducing waste.
• Though often seen as modern, its roots go back centuries.

1.Ancient Lean Practices


• Historical examples include the efficient construction
methods of the ancient Egyptians and the organized
production lines of the Venice Arsenal during the
Renaissance.

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2.Early 20th Century: Scientific Management

• Frederick W. Taylor's "Scientific Management" in the early 1900s


emphasized efficiency and process improvement, laying the
groundwork for future methodologies.

3.The Rise of Ford: Assembly Line Production

• Henry Ford revolutionized manufacturing with assembly line


production in the 1910s, incorporating the principle of flow,
a key lean concept, to reduce production time and costs.

7
4.The Toyota Way: Birthplace
of Modern Lean Thinking
• Post-WWII Japan, with its resource constraints,
saw the development of the Toyota Production
System (TPS) under Taiichi Ohno and Eiji Toyoda.
• TPS focused on eliminating waste ("muda"),
optimizing flow, and respecting the workforce,
leading to efficient, high-quality vehicle
production.
• Concepts like Just-In-Time (JIT) and Kaizen
(continuous improvement) originated from TPS.

8
5.Global Recognition and Adoption

• In the 1980s and 1990s, the success of Toyota and other Japanese
firms caught Western attention.
• An MIT study introduced "Lean Manufacturing" in "The Machine
that Changed the World," highlighting its advantages over
traditional methods and promoting its global adoption.
• Lean manufacturing's history reflects a pursuit of efficiency and
excellence, maintaining the core principle of delivering maximum
value while minimizing waste.

9
10
Q&A
1. Lean thinking is a methodology aimed at
delivering value to the end-user while
minimizing --------------.
2. Which of the following are the key
objectives of Lean thinking? Choose four
answers.
• Eliminate waste.
• Respect for people.
• Continuous improvement (Kaizen).
• Customer focus.
• Reduced risks.

11
What is Lean
If you were to improve a process 1% every day for 365 days, how many
times better would you be after one year?
A. 2-10 times
B. 10-20 times
C. 20-30 times
D. 30-40 times

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Daily Improve 1%

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