Page 29 - How To Implement Lean Manufacturing

10 Cha pte r T w o

• Using less inventory
• Consuming less space and
• Using less people

Even more importantly, a Lean process, be it the TPS or another, is characterized by
a flow and predictability that severely reduces the uncertainties and chaos of typical
manufacturing plants. It is not only financially and physically Leaner, it is emotionally
much Leaner than non-Lean facilities. People work with a greater confidence, with
greater ease, and with greater peace than the typical chaotic, reactionary—change-the-
plan-hourly-and-then-still-work-overtime-and-then-still-expedite-it-all manufacturing
facility.

Lean and the Toyota Production System
To further explore the depth of what a Lean Manufacturing system really is, we will
look deeply at the TPS. Not because the TPS is the best Lean system around, although
it may be. I can say it is the best I have seen. Rather, we will look at the TPS because it
is the best documented system and it has proven itself over a very long time. It has not
only proven itself but stands as the example of “Lean done extremely well.”

What Did Ohno Say about the Toyota Production System?
If we really want to understand what the TPS is, we certainly must listen to what its
creator has to say. In any discussion about the TPS, Ohno will be my arbiter. A great deal
has been written about Lean and the TPS, but some of it misses the point. If there is any
question about what Lean or the TPS is, we will use Ohno’s thoughts as the final word
on the topic. His most notable writing on the subject is his book, The Toyota Production
System, Beyond Large-Scale Production. In it, Ohno makes three key statements, which
when taken together define his TPS.

• “The basis of the Toyota Production system is the absolute elimination of
waste.” (pg. 4)
• “Cost reduction is the goal.” (pg. 8)
• “After World War II, our main concern was how to produce high-quality goods.
After 1955, however, the question became how to make the exact quantity
needed.” (pg. 33)
Taken together, we could then write a definition such as, “the TPS is a production
system which is a quantity control system, based on a foundation of quality, whose goal
is cost reductions, and the means to reduce cost is the absolute elimination of waste.”

The TPS and Lean Manufacturing Defined
I find that all of these definitions miss part of the essence of Lean Manufacturing. I do
not think Ohno defined it more carefully because oftentimes we do not feel the need to
define those things that are very near and very obvious to us. I believe others may not
define it better because they simply miss the point, while others may understand it but
not be able to articulate it. My definition of the TPS is a manufacturing system that: