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Contents
What is lean production?
Why has it been so difficult to decode? y
Issues of implementation p
Guardian 14.11.2008
Lauri Koskela 2009
The question
Why does the Toyota Production System ( (TPS) p ) perform better than conventional methods of production in car manufacturing?
Flow of materials
Human action
Input p
Production
Output
Decomposition
Materials, labor, machines Production Production process process
Products
Subprocess A
Subprocess B
Powerful assumption: decomposed subprocesses are mutually independent! Thus, the whole production effort can be integrated in an additive manner: by minimizing the costs of each department, function, section, and work station the total costs will be minimized minimized.
Lauri Koskela 2009
Sou ce Source: Schonberger (1996) World Class manufacturing: The Next Decade.
Car manufacturing
Figure from: Schonberger. 1996. World Class Manufacturing: The Next Decade.
Moving
Waiting
Processing A
Inspection
Moving
Waiting
Processing B
Inspection
Scrap
Flow view Fl i
Concept: Production is a flow, composed of transformation and other phenomena: inspection, moving, waiting First principle: Elimination of nontransformation phenomena (waste) Further principles: Time compression, variability reduction, etc. i bilit d ti t
Scientific method
(Sh h t & Deming 1939): It may b helpful t (Shewhart D i 1939) be h l f l to think of the three steps in the mass production process as steps in the scientific method. In this sense, specification, production, and inspection correspond respectively to making a hypothesis, carrying out an experiment and testing the experiment, hypothesis. These three steps constitute a dynamic scientific process of acquiring knowledge. Spear and Bowen (1999): whenever Toyota defines a specification, it is establishing sets of hypotheses that can be tested. Thus, the scientific method is followed followed.
Lauri Koskela 2009
Constantly evolving
Recent examples
A3 Monozukuri
A3
A3 (An A3 size standard paper) is used to visually explain problem solving processes, typically for kaizen events. It should flow as a story, explaining the PDCA steps of problem solving. h ld fl t l i i th t f bl l i It also keeps the visual record of past problem solving efforts.
Heading Plan Do
Check
Act
Footnotes
Monozukuri
monozukuri means h i th spirit t produce k i having the i it to d excellent products and the ability to constantly improve a production system and process. process. (JETRO) Monozukuri is a term used since the late 1990s to identify the cultural heritage that Japanese manufacturers have developed since the industrial revolution (Arai MEMA) revolution. (Arai, Similar to martial arts such as karate and bujyutsu, monozukuri requires continuous practice, effort, improvement and patience to master a skill or create a new skill to outperform others. (Arai, others (Arai MEMA)
Lauri Koskela 2009
Hitachi
Executive Officers [Effective January 1, 2007] [(b) Promotion/ (c) Change of Position] Etsuhiko Shoyama Chairman
President, General Manager of Supervisory Office for MONOZUKURI Executive Vice President and Executive Officer, in charge of Research & Development, Business Incubation, Hitachi Group Chief Innovation Officer and Hitachi Group Chief Technology Officer Executive Vice President and Executive Officer, General Manager of g Compliance Division, in charge of Corporate Planning & Development, Legal & Corporate Communications, Management Audit, Procurement
Takashi Hatchoji
Takashi Executive Vice President and Executive Officer, Chief Hitachi Group MiyoshiKoskela2009 Headquarters, in charge of Business Development and Finance Lauri Lauri Koskela 2008
TPS/Lean production
1. 1 Leads to better products, more efficient production, products production thanks to a more valid concept of production 2. Built-in continuous improvement p 3. Constantly evolving Lean production is a theory-based but practice-driven theory based, practice driven innovation Increasingly applied in Western manufacturing, but understanding and i l d t di d implementation i th W t l t ti in the West lag behind in comparison to Japan The neglect of theory has slowed down the diffusion of lean manufacturing in the West for 15 20 years Focus on the transformation of mass manufacturing into lean manufacturing
Lauri Koskela 2009
Budget: The total cost is decomposed with regard to individual work p g packages and tasks g
Decision rule: If each task is kept within its budgeted cost, the whole project is completed in budget
Lauri Koskela 2009
Lean manufacturing
Lean construction
Outpu ut
Week 1
Week 2
Week 3 Time
Output
Week 1
Week 2
Week 3
Time
Critical path network: A task is started after the completion of the preceding task in the network (end-start relationship) (end start
Preceding task
(In site practice: A task should be started when the master schedule indicates that)
Task
Preceding task
Other inputs
Task
Assembly tasks
Consider a task with one week duration, with seven prerequisites/input fl ith i it /i t flows Let us assume that the reliability of each y input flow is 95 % during one week The probability of having no deviation in any input flow during the week, when starting and carrying out the task, is , , 0,957 = 0,70.
Lauri Koskela 2009
Making-do Making do
M ki d as a waste refers to a situation where Making-do t f t it ti h a task is started without all its standard inputs, or the execution of a task is continued although the availability of at least one standard input has ceased. ceased The term input refers not only to materials, but to all other inputs such as machinery tools machinery, tools, personnel, external conditions, instructions etc. Making do buffering, Making-do is equivalent to negative buffering i.e. the waiting time for a part is negative
Outpu ut
Week 1
Week 2
Week 3 Time
45%
35%
Budgeted M i i t t l 6 200 000 B d t d Margin in total: $ 6,200,000 Realized Margin in total: $ 9,200,000
25%
% 15%
-5%
A contractor in Finland reports on using Last Planner: p g Antti Husso: Last Planner not only facilitates one's own work, but especially improves the productivity on site.
Lean Construction
Ends
Elimination of making-do g Lead time reduction (inventories, buffering)
M Means
Last Planner system of production control Practices and methods in lean production, when applicable pp
Conclusion
F one-of-a-kind production and For f ki d d ti d construction, we need theory-based development of lean manufacturing concepts do not cover all that is needed (although we increasingly find that manufacturing concepts are applicable in construction)
Issues of implementation
Rather/also the focus should be on: operational design, p g , prefabrication and site production processes where the end product is created L Lean principles can b used everywhere, even i a point i i l be d h in i t wise way but the results are increasingly better, the gg pp bigger the area of application
Lauri Koskela 2009
Thank You!
Questions? Comments?