Lean Production Essay

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HISTORY
Being among the first people to develop the idea behind lean production, Henry Ford utilized the concept of "continuous flow" on the assembly line for his Model T automobile where the standards of production were tight so that each stage of the process fitted together with each other stage efficiently resulting in little waste. It was likewise a "push" process, where Ford set the level of creation, rather than a "pull" handle drove by demand of the customer. This resulted in vast inventories of unsold vehicles, at last bringing about loads of money wasted.
Competing businesses decided to catch up with Ford's ideas but they soon realized that the inflexibility of the system was an issue. The Toyota Production System (TPS) was then developed
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Benefits of Lean Production
The idea of lean production is a strongly effective for any business that needs to end up and additionally stay in the competition.
Why? Since waste = cost
Less waste accordingly implies lower costs, which is a fundamental part of any competitive business. The concept of over-production is making more than that is required – prompts excess stocks.
• Waiting time: hardware and individuals standing idle waiting for a production process to be finished or arrival of resources.
• Transport: moving assets (individuals, materials) around pointlessly
• Stocks: is usually held, as a buffer but should not be in excessive amounts.
• Movement: a seemingly busy worker that does not actually add any value
• Defects: yield that does not achieve the required quality standard – regularly a critical cost to an uncompetitive
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This was the seed for automation and Jidoko. Just in time (JIT), is a process created by Toyota and started back in 1934 when they shifted from the textiles industry to automobile industry. Kiichiro Toyoda, founder of Toyota Motor Corporation, shifted the casting work of the engine and identified many faults in the manufacture. As a result, he decided to stop repairing and start thoroughly investigating each stage of the manufacturing process. Once Toyota signed its first truck contract in 1936 with the Japanese government, the manufacturing processes hit a new problem and he built the "Kaizan" development

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