A History Of Lean From Manufacturing To Software Development

The fivestep thought process for guiding the implementation of lean techniques is easy to remember, but not always easy to achieve Specify value from the standpoint. Advanced Manufacturing. Advanced Manufacturing Media is a leading source for news and indepth technical information about advanced manufacturing in North America. A History Of Lean From Manufacturing To Software Development' title='A History Of Lean From Manufacturing To Software Development' />History of Lean Manufacturing Lean Manufacturing Tools. Lean Manufacturing History. When people think of lean manufacturing they normally think that it began with Toyota and some go as far back as Ford and his production lines for the Model T ford, but depending on how you define lean, it has a very long history. Origins of Lean. Ford put many ideas together when he first designed his production line for the model T Ford, however he did not invent very much of it himself. The ideas of having interchangeable parts and the like were not new to Ford, they had been around for a long time, the principles had been used by Eli Whitney to manufacture muskets at the end of the 1. Century. Production Lines were far from new, King Henry the 3rd watched the hourly production of Galley ships in 1. Marc Brunel father of Isambard created production lines for the royal Navy in 1. Fredrick Taylors work on scientific management investigated workplace efficiencies and Frank Gilbreth  looked at motion studies. Both of their works influenced the design and functioning of the Ford production lines. However Fords production lines were not flexible and they fostered very much a them and us attitude between the management and the workers on the lines, it was the management that did the thinking and the workers did as they were told. Fords methods however worked for mass production and were highly effective during world war 2 where Ford helped to build Bombers at the Ford Willow Run plant and Boeing. Development of Lean Manufacturing. Development of the Toyota Production System. Sakichi Toyoda invented a weaving loom that was able to stop when it detected a broken thread. This enabled a single worker to be able to monitor several machines as the operator only had to intervene on an exceptions basis. This was the start of Autonomation or Jidoka automation with a human touch, one of the important parts of the Toyota Production System and hence Lean Manufacturing. Through selling the patents to this invention to Platt Bros in Yorkshire the Toyoda family were able to exit the textiles business and fund the start up of their automotive company Toyota. Toyota and the Quality Gurus. A History Of Lean From Manufacturing To Software Development' title='A History Of Lean From Manufacturing To Software Development' />After world war two the US helped Japan rebuild its manufacturing capability, they did this by sending a number of consultants to provide aid and advice. The people that they sent were people like Deming who had no success at getting the Americans to listen to his philosophy with regard to Quality and Management. The Japanese however listened and learned, the Deming award now being the greatest award a company in Japan could gain. Through Deming, Juran, Shewhart and the other consultants that were bought into help them Toyota and the other Japanese companies learned the importance of quality and satisfying their customers. They also learned the importance of involving their entire workforce in making improvements. Quality and respect for their people became very important for Toyota. Toyota also listened and developed the concept of Just in Time JIT, together with Jidoka this formed the two main pillars of the fledgling Toyota Production System TPS. Eiji Toyoda and Taiichi Ohno visited Ford to gain a greater understanding of how Ford was run, they also found huge inspiration from of all places American supermarket chains From Ford they saw how production lines worked and how processes could be broken down into manageable steps. They also discovered processes and ideas such as CANDO Clean up, Arrange, Neatness, Discipline, Ongoing Improvements which became the basis for their 5. D0%91%D0%B5%D1%80%D0%B5%D0%B6%D0%BB%D0%B8%D0%B2%D0%BE%D0%B5-%D0%BF%D1%80%D0%BE%D0%B8%D0%B7%D0%B2%D0%BE%D0%B4%D1%81%D1%82%D0%B2%D0%BE.jpg' alt='A History Of Lean From Manufacturing To Software Development' title='A History Of Lean From Manufacturing To Software Development' />S system. Kanban enables pull systems. From the supermarkets they saw how the shelves only got replenished when customers removed produce this ensured that the supermarket only had to purchase what the customers were buying  and could minimise their stocks. Lean-Innovation.jpg' alt='A History Of Lean From Manufacturing To Software Development' title='A History Of Lean From Manufacturing To Software Development' />Something that was vital in an economy that was short of resources. This triggered the development of Just in Time and Kanban systems. By the 1. 95. 0s the Toyota Production System was well into development, and Toyota was beginning its journey to out compete the rest of the world with regard to producing reliable quality cars. In the 1. 96. 0s Shigeo Shingo developed the technique of Pokayoke mistake proofing  and Ishikawa devised the concept of Quality Circles giving the employees far more involvement in molding the future of Toyota. History of Lean Video. Lean and the West. By the early 1. 98. Japanese were out competing them and companies started to take a long hard look at what they were doing. Various consultants began to try to introduce their versions of the Toyota Production System under westernized names such as Continuous Flow Manufacturing, Stock less production and World Class Manufacturing. Companies in the West also tried to determine exactly what it was about Toyota that made them so good so they started taking individual ideas and trying to implement them in isolation such as quality circles or kanban systems. It was not until 1. MIT study were published in the book titled The Machine that Changed the World by Womack and Jones that the world was introduced to the term Lean Manufacturing. Since then the name has stuck and Lean has gone from a Must Have in the Automotive industry to a technique that has been applied across almost every industry. There are now many publications out there explaining the philosophy of Lean Manufacturing and the various Lean Tools in huge detail, there are also many consultancies out there selling business improvement through the application of Lean Manufacturing. The Rise and Fall and Rise of Lean. Like most management Fads and Philosophies Lean saw huge popularity at the start with many consultants appearing on the scene throughout the 8. S through to World Class Manufacturing. These consultants were jumping very much on the bandwagon of helping companies to compete effectively against the by now superior Japanese imports. However many of these consultancies had very little idea of what lean was really about and no experience of implementing itSo many of these consultants would implement what they understood to be lean and try to make as many savings as they could so that they looked good to the companies that hired them. The savings more often than not vanished after a few months as soon as the consultants left the company and moved onto the next. Lean therefore quickly gained a reputation as something that was implemented to remove people and cut costs and was not seen as something that was sustainable in the west. Many attributing the success of Lean in Japan to the attitude of the Japanese themselves, even though some of the most productive Toyota plants were actually located in places such as the States and were staffed by non Japanese. In House 5. S Training Course. Lean is still seen as a must have within the automotive industry and throughout its supply chain. It has also slowly been adopted into many other industries and even service areas. Lean for Health Care and even Programming are now areas where Lean is seen to be growing rapidly in popularity. Even so many Consultants have seen the need to change the name to distance themselves from old bad press and misconceptions now we have Agile manufacturing which focuses on being able to respond rapidly to changing customer demand and even Lean Sigma which seeks to combine the power of lean with the analytics and cost savings of Six Sigma. Writing Data To A Text File In Python more.