Dipl.-Ing.oec. Dennis Behnke, LSSMBB

Introduction to Lean Management

Lean Six Sigma Yellow Belt Course

The Automotive Industry: Trendsetter for Production Concepts and Technologies

The cradle of the ‘industry of industries’: Early automobiles were mostly custom-made in craftsmen's workshops.

Benz Patent-Motorwagen Nr. 1(Benz & Cie., Mannheim, Germany)

P2D (Daimler-licensed engine by Panhard & Levassor, Paris, France)

The First Revolution of the Automobile Industry and the Rise of the Big Three

After WW2, more than ¾ of the global automobile production was based in the United States.

Craft Production

- Interchangeability of parts- Moving assy line- Division of labor

Henry Ford (1863-1947)

Alfred Sloan (1875-1966)

Mass Production

The ‘Big Three’

1st Automobile Revolution

The Japanese Automobile Industry after WW2

After WW2, the Japanese automobile industry had but poor circumstances. Target: Many models in small quantities.

Diversified Consumer

Requirements Shortage of Capital and Resources

Dominance of US

ManufacturersConfident

Labor Force

Nagoya

The Decline of the US Automobile Industry and the Rise of Japanese Lean Production

From the 1960s onwards, the Japanese auto-industry gained market share, and Toyota became the leading global automobile manufacturer.

[WomackJones90]

The Second Revolution of the Automotive Industry Quantified

GM Framingham Toyota TakaokaGross assy hours per car 40.7 18.0Adj.* assy hours per car 31 16Assy defects per 100 cars 130 45Assy space per car 8.1 4.8Avg inventories of parts 2 w 2 h

*Only standard activities which were comparable in both plants[WomackJones90]

Japanese factories seem to produce cars in a shorter time, with lower costs,and a higher quality.

The Japanese Pioneers of Lean Production

豊田 英二とよだ・えいじ

Toyoda Eiji(1913-2013)

豊田佐吉とよだ・さきち

Toyoda Sakichi(1867-1930)

大野耐一おおの・たいいち

Ohno Taiichi(1912-1990)

Founder of Toyota GroupInventor of Jidoka textile looms

Launched Toyota’s automobile production,inventor of Just-in-Timeprinciple

Toyota Group executive,father of the Toyota Production System

豊田喜一郎とよだ・ きいちろう

Toyoda Kiichiro(1894-1952)

Long-term president and chairman of Toyota Group

新郷 重夫しんごう・しげお

Shingō Shigeo(1909-1990)

Engineer at Toyota, made several key contributions (Kaizen, SMED, …)

The Toyota Production System (TPS) as the First Framework of Lean Production

Entablature

Capital

Column

Stylobate

Stereobate

トヨタ生産方式とよたせいさんほうしき

Toyota seisanhōshiki

→ Line ⭮ Cell(Base)