The Story Of Lean Production : Toyota 's Secret Weapon

Lean manufacturing is the production of goods using less of everything than in mass production: less human effort, less manufacturing space, less investment tools and less engineering time to develop a new product. A company becomes lean by continuously increasing its capacity to produce high-quality goods while simultaneously decreasing

Production practices have had an important role in satisfying the dynamic market. Many approaches have being developed in order to respond effectively to specific business requirements. In fact, some areas of management have focused its study on the overseeing, designing, and controlling the process of production in an effort to find the best methodology that ensures the business success and performance. However, complexities arise in this field because many variables such as costs, inventory, scheduling, suppliers, etc have to be considered in any business. Lean approach and the traditional approach are two points of view that aim to address this complexities, and those will be examined in this essay.

Prior to Toyota’s Production System, the company was efficient, yet could not compete with large American competitors such as General Motors and Ford. Therefore, management realized that if the company was to be successful not only in Japan, but globally it would need to improve its manufacturing process. Consequently, the company developed Toyota’s lean manufacturing process, which is still used today. The LMP was used to eliminate waste in the entire production process to become more responsive to market demand and produce high quality products economically. In order to provide superior products, Toyota implemented many revolutionary strategies. For example, the company started, or invented, the Just-in-Time Manufacturing process. The JIT process, according to our text, is used to reduce inventory costs by scheduling supplies to arrive just in time to enter the production process or as inventory stock is depleted (Hill et al., 2015). Toyota used the just-in-time system to improve its supply chain management, which drastically decreased costs and increased the company’s production facilities output as compared to its competitors. In addition to JIT, the company introduced a concept known as Kanban that was included within the new JIT system. The Kanban system was developed by Ohno and was used to arrange for components and/or assemblies manufactured at Toyota to be delivered to the assembly floor only when needed, not before (Hill et al., 2015). Essentially the Kanban

According to the main challenge of inefficient production, i.e. Michelin with improving production efficiency based on maintaining high quality, the theory of lean production system will meet the direction of development in Michelin production management. Thomas (1996) pointed that lean production can reduce overall costs, especially indirect costs, while remaining quality standards and reducing manufacturing cycle time. The goal of Lean production is maximization of enterprise interests, and timely manufacturing and eliminating all waste in the production process of raw materials procurement, storage, transportation, production and packaging(Heizer, Render and Munson, 2017). There are four elements from the lean production theory will be utilized to develop the analysis: value stream, pull production system, waste elimination and total quality management.

Chase et al. (2006) state that “lean production is an integrated set of activities designed to achieve high-volume production using minimal inventories of raw materials, work-in-process, and finished goods” (p. 471). The essential components of lean production are surplus elimination, constant work-flow, and consumer appeal. The minute these components are in the neighborhood of supply, quality and cost, this outlines the groundwork for a lean production organization. A Japanese plan of continuous progress named the Kaizen is responsible for the lean production idea. Riordan can adjust the lean production concept by employee empowerment and advancement, staying focused on making processes stronger, impact of consumer relations, rapid merchandise growth and production, and cooperation with suppliers are the imperative strategies of Riordan managing lean. Features of a lean enterprise include a combined single piece continuous workflow and near incorporation of the entire value series from raw material to finished product. In addition, demand drives production rather than predictions. This means that manufacture designing is by consumer demand or appeal and not to become system loading or strict work flows on the company floor. This will help Riordan keep minimal inventories at each step of the production process. It is also important to know that having a working participation by employees involved in

In the book, The Toyota Way, Jeffery Liker provides an in-depth account of, not only the tools and methods of Toyota’s Production System, but also a broader explanation of the principles at work in the Toyota culture. This philosophy of manufacturing can be summarized through two important pillars: “Continuous Improvement” and “Respect for People.” These pillars help define Toyota’s approach to doing business, were the focus is on continuous learning and embracing change. By incorporating this ideology and its 14 principles into its manufacturing operations, Toyota has become the greatest manufacturer in the world. In this essay, I will provide a synopsis of Toyota’s 14 principles and also offer my own account of lean manufacturing at CNH Industrial.

Lean manufacturing is the production of goods using less of everything than in mass production: less human effort, less manufacturing space, less investment tools and less engineering time to develop a new product. A company becomes lean by continuously increasing its capacity to produce high-quality goods while

Under the lean production approaches, a number of factors are essential to the process for

The lean thinking has been established in a well manner in the competitive world. The countless business industries have proved their effective growth in terms of brand recognition and in terms of the good profit amount with the effective application of the lean production system in their operational activities. Toyota has added their name in the application of the lean thinking in their production process first in the global competitive market. The book “the Gold mine” written by Freedy and Michael Balle is a definite attempt to highlight the challenges that the leaders are facing in the perfect transformation of the lean thinking in their operational activities. This essay has discusses the direct connection between the content the

Countess firms have taken up lean production in their manufacturing process. This is because the process is known to have countless benefits when effectively implemented. For lean production to be effectively implemented, some principles have to be considered. These principles have been discussed in detail in this paper. The different principled in lean production as well as the different principles in effective business communication. How they are related and hence how they lead better production and hence better output from the firm.

It is a present-day instance of the recurring theme in human history toward increasing efficiency, decreasing waste, and using empirical methods to decide what matters, rather than uncritically accepting pre-existing ideas. As such, it is a chapter in the larger narrative that also includes such ideas as the folk wisdom of thrift, time and motion study, Taylorism, the Efficiency Movement, and Fordism. Lean manufacturing is often seen as a more refined version of earlier efficiency efforts, building upon the work of earlier leaders such as Taylor or Ford, and learning from their mistakes.

 Comparing and contrasting the implementation of Lean Manufacturing in manufacturing and service industries:...................................................Page no.8-9

This paper deals with the production systems of two major leaders in the automobile market. Mass production is briefly touched up on and its advantages and disadvantages are discussed. Lean production is the emerging trend, which talks about minimizing waste and increasing production. We have also thrown light on when to use lean and mass

Lean manufacturing originated long before Toyota and Ford, however the thought that it originated with Toyota is flattering since they are the ones who perfected it. By creating the Toyota Production System (TPS), Toyota found a better way to produce large quantities of product efficiently with eliminating the waste factor and while cutting down cost. Taiichi Ohno a former Toyota vice president promoted the idea of JIT (Just-in-Time) which means “producing the necessary units in the necessary quantities at the necessary time.” (Monden) Which leads to Toyota’s ultimate goal in the TPS is to improve productivity for better return in investment. To have continuous flow in a production system Toyota sought out to achieve the concept of JIT and autonomation . Since the TPS is what creates the parts who monitors the JIT system? The kanban system which is an informational system that controls quantities being produce in each process. As the discussion carries on throughout this paper about Toyota and their use of the kanban system the topic

In our economy today we face major issues dealing with manufacturing with how do we build or retain the capacity and competitive edge in the global market? Well manufactured is measured in a number of ways, such as statistics and analyses. These metrics range from the amount and type of goods produced, to a detailed breakdown of the people who contribute to this production, to the economic impact of both. But knowing the market is tough using lean manufacturing techniques as a tool any company can maintain control of an operation of any business.