Unit 2 Lean - Evolution and Steps

Question 1

Brief history of Lean

Answer 1

1850-1996

Question 2

1850

Answer 2

Eli Whitney and interchangeable parts

Question 3

1911

Answer 3

“Principles of Scientific Management”, Frederick Taylor

Question 4

1911.

Answer 4

“Motion Study”, Frank Gilbreth

Question 5

1919

Answer 5

“Applied Motion Study,” Frank & Lillian Gilbreth

Question 6

1913

Answer 6

Mass Production / Economies of Scale

Question 7

1915

Answer 7

Inventory Mangement (EOQ)

Question 8

1950s

Answer 8

Post-war reconstruction in Japan

Question 9

1977

Answer 9

Oil Embargo Japan in Recession

Impact of TPS

Question 10

1980s

Answer 10

Toyota joint venture with GM - New United Motor Manufacturing Inc

Question 11

1990

Answer 11

“The Machine that Changed the World,” James Womack & Daniel Jones

Question 12

1996

Answer 12

“Lean Thinking,” James Womack & Daniel Jones,

Identification of Lean Principles

Question 13

Henry Ford on Inventory as Waste . . .

Answer 13

“Ordinarily, money put into raw materials or into finished stock is thought of as live money. It is money in the business, it is true, but having a stock of raw material or finished goods in excess of requirements is waste - which, like every other waste, turns up in high prices and low wages.”

Question 14

Henry Ford on Motion as Waste

Answer 14

“The thing is to keep everything in motion and take the work to the man and not the man to the work.”

Question 15

Lean Process 5 Steps (SIMPA)

Answer 15

• Specify Value
• Identify Value Stream
• Make it Flow
• Pull
• Always Improving

Question 16

Step 1- Specify Value

Answer 16

• Identify Value- in the customer’s perception - and for which he is willing to pay
• Distinguish between value-to-business and value-to-consumer
• Use QFD, Kano Model, focus groups, and other tools to identify attributes of value.