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Build Your Lean Production System


Mass production has had a long run. The standardization of parts enabled this. That meant the craftsman did not have to modify every part of a car. But like lots of things, mass production is yesterday’s technology. It’s time to Build your Lean Production system.

Taiichi Ohno, the great Japanese engineer, Built the first Lean Production System by determining a way to aggressively remove defects from a product. He would have everyone on the assembly line inspect the products and then halt the assembly line, by an andon call, if a defect was found to determine the source cause of the defect and rectify it.

Of course, this was very painful as it caused a lot of stoppages. In fact, Toyota’s Lean Production system still averages about 800 stops a year in their assembly lines. Above all, the rapid directional change from their Continuous Improvement program can cause stops to increase while less change causes stops to decrease. Toyota uses the number of stops a year as a metric of balance between change and no change. When you Build Your Lean Production System you will determine the right rate of change for your system. For Toyota, it is about 800 andon calls a year that is a healthy number, balancing the impact of change.

Lean Production has another advantage. The advantage is that it produces a product for a customer. Mass Production just produces products. A major disadvantage of Mass Production is the buildup of inventory between departments. Lean Production alleviates this buildup of waste.

It is possible to put together your Lean Production system, and that is what this video discusses:

Lean Production is the future. Every current major high production automobile must use Lean Production to be competitive. Whether you are producing a ship or a hula hoop, Lean Production is the future of manufacturing.

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