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History of Lean. Agile Tour Ho Chi Minh 2012 Kiro HARADA. 原田 騎 郎. Kiro HARADA Agile Coach Domain Modeler SCM Consultant Twitter: @ haradakiro. What is Lean?. l ean | liːn | Adjective

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history of lean

History of Lean

Agile Tour Ho Chi Minh 2012





Agile Coach

Domain Modeler

SCM Consultant

Twitter: @haradakiro

what is lean
What is Lean?
  • lean|liːn|
  • Adjective
  • (of a person or animal) thin, especially healthily so; having no superfluous fat: his lean, muscular body.

• (of meat) containing little fat: lean bacon.

• (of an industry or company) efficient and with no wastage: staff were pruned, ostensibly to produce a leaner and fitter organization.

Oxford English Dictionary

origin of lean
Origin of Lean
  • 1988 - Paper “Triumph of Lean Production System”
    • Study on Toyota Production System
  • International Motor Vehicle Program(IMVP) at MIT Sloan School
  • 1990 - The Machine That Changed The World
    • James P. Womack
    • Toyota was ½ size of GM
toyota production system tps
Toyota Production System (TPS)

What is Toyota Production System (TPS)?

what do y ou know about tps
What do you know about TPS?
  • Just In Time
  • Kanban
  • Muda
  • Heijunka
  • Andon
  • 5S (Seiri, Seiton, Seisou, Seketsu, Shituke)
  • Go and See (GenchiGembutsu)
  • 5 Times Why
  • Jidoka
  • Kaizen
  • Pull
  • SMED(Single Minute Exchange of Dies)
  • 1 piece flow
  • Value Stream Mapping
  • Takt Time
house of tps
House of TPS

Quote from S. Kuroiwa

toyoda type g automatic loom 1924
Toyoda Type G Automatic Loom (1924)


toyoda type g automatic loom 19241
Toyoda Type G Automatic Loom (1924)

What was different from other Looms?

  • Non-stop Shuttle Change
  • Automatically STOPs if a thread breaks

Throughput of Manufacturing Good Product is far more important than the Machine Utilization Rate.

Toyoda sold Patenet of Type G and used to seed Toyota Motors Co. Ltd.


toyota was almost bankrupt
Toyota was almost bankrupt

In 1950,a major labor dispute in Toyota Motor.

Most of Executives including the founder Shoichiro Toyoda resigned.

Toyota has no money to buy enough machines, lines, parts and hire managers at that time.

tps core concepts
TPS Core Concepts
  • Autonomation (Autonomous Automation)
  • Just in time
    • SMED
    • Kanban
  • Self Management
  • People Development
value stream mapping
Value Stream Mapping

(Figure to be Added)

Map of Value Added Work


Autonomous Automation

Automation with Human Intelligence

(Build Quality In)



  • Automation to improve operational ratio
  • Autonomation to improve through-put
7 wastes 7 muda
7 Wastes – 7 Muda
  • Transportation
  • Inventory
  • Motion
  • Waiting
  • Over-processing
  • Over-production
  • Defects
muri mura muda
Muri Mura Muda
  • ムリMuri Overload / Overburden

  • ムラ Mura Unevenness

  • ムダMuda Waste

You need to eliminate Muri first with KAIZEN to eliminate Muda.

continuous flow
Continuous Flow
  • Leveled Production – Heijunka (平準化)
  • Muri – Mura – Muda

are eliminated end to end

  • Continuous Improvement
  • Eliminate
  • Combine
  • Replace
  • Simplify
the five s s 5s
The Five S’s (5S)
  • Seiri – sort, sort out, organize
  • Seiton – straighten, stabilize, make it neat
  • Seiso – scrub, shine, clean
  • Seiketsu – systemize, standardize
  • Shitsuke – sustain, self-discipline, discipline
all about people
All about People

When do you have a strong motivation for work?

Survey in Japanese and U.S. automakers showed the same result.

  • Autonomy
  • Responsibility
  • Achievement
  • Opportunity
  • The work itself
  • Advancement
  • Recognition
how can you use lean tps
How can you use Lean / TPS
  • In your software development?
  • In your organization?
  • With your career?
because tps stands for
Because TPS stands for

Thinking People’s System

thank you
Thank you

“Open the door, it’s a large world outside.”

Sakichi Toyoda