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LEAN is primarily a method to reduce waste and is based on a mindset.

Introduction

The Lean method is a set of tools for:

Eliminating waste to increase our efficiency,

OEE and reduce our Kosu

All based on a state of mind linking quality and productivity

The TPS House

Popularized by Jeffrey Liker in his famous book The Toyota model, the house TPS is the representation of the production system set up by Toyota. The concept of “house” was built in 2001 by Toyota. The idea is to represent a company like a house:

  1. Built on solid foundations: Mindset, levelling, Kaizen and standardization
  2. Allowing to support the walls: the Just In Time and the Jidoka
  3. Enabling us to be successful in our innovation processes
  4. Having at its center, all the attentions on strong management values

 

The Foundations

Lean Way

You will find all the items on the history, the mindset of the Lean and the founding concepts wastes, the PDCA…).

Kaizen

Translated by continuous improvement, this foundation includes all elements of the TPM (improvement of maintenance), TQM (Quality Improvement) and problem solving.

Standardization

Starting Point for improvement, standards are a key focus of the TPS and help to stabilize processes. The methods and tools are numerous: 5S, time Analysis, visual Management

Heijunka

In order to smooth the customer demand over time, this is the essential concept to limit the effects of the variability of the customer demand.

The walls

Just In time

Probably the best known concept of the TPS, the Just In Time aims to set up a system to produce only the necessary quantity at the right time and at good quality. The key tool of this concept: the Kanban.

Jidoka

The Jidoka Is the second pillar of the Lean House. As a cultural tool par excellence, it aims to stop actions as soon as there is a problem to solve it in the immediate future. Often complex, it is essential to the proper functioning and improvement of the system. Tools such as the Poka Yoké or the Andon system are found.

The roof

Lean 6 Sigma Innovation

The roof represents the ” ultimate ” objective of Lean, which is the ” perfect ” product design for the customer: Best quality, lowest price and shortest delay. The principles of Kano or the Robust design are among the most well-known tools.

The heart of the house

Lean 6 Sigma Management System

In the heart of the house, the Lean 6 Sigma management is an important source to achieve customer satisfaction. We will find the guiding principles of the management and the roles of each in the process.

 

 

 

 

 

Lean on video

 

Sources

1-G. Fliedner (2012)-Leading and managing the Lean management process

2-J. L. Peaucelle (1999)-Division of Labour: Adam Smith and the encyclopaedists observing the manufacture of the pins of Normandy

3-A. C. Manucy (1985)-Artillery through the ages

4-J. Hughes (1986)-The vital few: the entrepreneur and American Economic progress

5-R. Boyd Gordon, P. M. Malone (1994)-The texture of industry: an archaeological view of the industrialization of North America

6-R. Kanigel (2005)-The One best way: Frederick Winslow Taylor and the Enigma of efficiency

7-S. Olson (1997)-Young Henry Ford: A picture history of the first forty years

8-S. K. Land, D. B. Smith, J. V. Walz (2008)-Practical support for Lean Six Sigma software Process definition

9-D. Dinero (2005)-Training within industry: the foundation of Lean

W. Mass, A. Robertson (1996)-From Textiles to automobiles: Mechanical and Organizational Innovation in the Toyoda Enterprises, 1895-1933

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