The title of this chapter is somewhat awkward. By another translation you could read it as “Improvement means doing what is rational” or “Kaizen means following reason”. But here Taiichi Ohno is engaging in a bit of word play. The Japanese for rationalization, in literal translation means “make it fit
Month: May 2006
It’s not easy to read so much about the dark side of Lean. I’ve received e-mails this week from readers who are upset that I would post attacks on Lean manufacturing and kaizen. It’s no fun to learn terrible things about your favorite production system, but growth and learning is
Today we continue exploring the dark side of Lean as we interview Darius Mehri, author of Notes from Toyota-land. Darius is an American who spent three years working as an engineer in Japan at a Toyota group company. He changed the name of the company in his book to “Nizumi”.
Many of those exposing the dark side of Lean production take aim at “Lean production” as defined in the book The Machine that Changed the World. This book compares the Japanese and U.S. automotive industries and identifies best practices. It claims that it is inevitable that all manufacturing eventually become
Kanban is a material and information flow management tool. They are typically cards attached to containers of parts. The cards contain information about the parts and these cards are reused, traveling with parts. Kanban are used to control the minimal amount of inventory in the system. It is based on
Each day this week we will examine aspects of The Dark Side of Lean. Today’s theme is “War, Oil and Lean Production” – admittedly an extreme Left perspective based on Marxist thought and the examination of a murder-suicide at a Jeep factory in January 2005. Why should we spend any
This week started with an article about the top 5 reasons for using 3P. Requests from readers took us deeper into SMED and jidoka – all aspects of Lean manufacturing and machines. Without planning it the theme for the week was the “mechanical side” of Lean manufacturing. Next week I
Delving deeper into themes related to Production Preparation Process (3P) today I’ll explain what is meant by the “5 Steps of Jidoka” mentioned number sixteen of the 16 Catch Phrases of 3P. Fist some background on jidoka. Jidoka is a pillar of the Toyota Production System and an innovation resulting
Taiichi Ohno begins the chapter by saying “In order to achieve Just in Time you need to solve your changeover problems and reduce lot sizes. Forging processes are the most difficult.” This chapter should really be titled “Toyota Learned How to Do Forging Changeovers in Brazil”. It’s an interesting story.
My apologies for introducing a new term with out explaining it yesterday. Thanks for asking Ben. The 16 Catch Phrases of 3P are used as guidelines for designing processes according to Lean manufacturing principles of JIT (Takt, Flow, Pull) and Jidoka. As a result of a successful 3P workshop following