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
Facebook: facebook.com/harada.kiro
What is Lean?
•  lean |liːn|
•  AdjecAve •  (of a person or animal) thin, especially healthily so; having no superfluous fat: his lean, muscular body. • (of meat) containing liOle fat: lean bacon. • (of an industry or company) efficient and with no wastage: staff were pruned, ostensibly to produce a leaner and fi7er organiza:on. Oxford English DicAonary
Origin of Lean
•  1988 -­‐ Paper “Triumph of Lean ProducAon System” –  Study on Toyota ProducAon System •  InternaAonal 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 ProducAon System (TPS)
What is Toyota ProducAon System (TPS)? What do you know about TPS?
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Just In Time Kanban Muda Heijunka Andon 5S (Seiri, Seiton, Seisou, Seketsu, Shituke) Go and See (Genchi Gembutsu) 5 Times Why Jidoka Kaizen Pull SMED(Single Minute Exchange of Dies) 1 piece flow Value Stream Mapping Takt Time House of TPS
Quote from S. Kuroiwa
Toyoda Type G AutomaAc Loom (1924)
hOp://commons.wikimedia.org/wiki/File:1924_Non-­‐Stop_ShuOle_Change_Toyoda_AutomaAc_Loom,_Type_G_1.jpg
Toyoda Type G AutomaAc Loom (1924)
What was different from other Looms? •  Non-­‐stop ShuOle Change •  AutomaAcally STOPs if a thread breaks Throughput of Manufacturing Good Product is far more important than the Machine UAlizaAon Rate. Toyoda sold Patent of Type G and used to seed Toyota Motors Co. Ltd. hOp://commons.wikimedia.org/wiki/File:1924_Non-­‐Stop_ShuOle_Change_Toyoda_AutomaAc_Loom,_Type_G_1.jpg
How did Toyota come up with TPS?
Toyota was almost bankrupt
In 1950, a major labor dispute in Toyota Motor. Most of ExecuAves including the founder Shoichiro Toyoda resigned. Toyota has no money to buy enough machines, lines, parts and hire managers at that Ame.
TPS Core Concepts
•  AutonomaAon (Autonomous AutomaAon) •  Just in Ame –  SMED –  Kanban •  Self Management •  People Development Value Stream Mapping
Map of Value Added Work Describe how value creaAng processes connect together. Value Added Work
Value Added Work Incidental Work Non Value Added Work AutonomaAon
Autonomous AutomaAon AutomaAon with Human Intelligence (Build Quality In) 自動化(AutomaAon) 自働化(AutonomaAon) •  AutomaAon to improve operaAonal raAo •  AutonomaAon to improve through-­‐put
7 Wastes – 7 Muda
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TransportaAon Inventory MoAon WaiAng Over-­‐processing Over-­‐producAon Defects Muri Mura Muda
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Muri Overload / Overburden ↓ Mura Unevenness ↓ Muda Waste You need to eliminate Muri first with KAIZEN to eliminate Muda. ConAnuous Flow
•  Leveled ProducAon – Heijunka (平準化) •  Muri – Mura – Muda are eliminated end to end Kanban
Kanban
KAIZEN 改善
What KAIZEN are you doing?
-­‐  Code Reviews? -­‐  Pair-­‐Programming? -­‐  RetrospecAves? -­‐  Release Checklists? -­‐  Bug Tracking Systems? -­‐  StandardizaAons?
Are they Sustainable?
•  Many Say “Yes, of course” Then I will ask another quesAon.
Can you do your KAIZEN
•  10 Ames more? •  100 Ames more? •  100,000 Ames more?
In case if you answer ‘NO’
• You are not doing KAIZEN / 改善
ConAnuous Improvement
•  You need to be able to do KAIZEN conAnuously.
KAIZEN is about reducing inputs
•  Reduce Inputs – While keeping • Same output • Same or BeOer Quality Do less work/acAvity Use less resource to deliver same results! Where Muda come from
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•  ムラ
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Muri Overload / Overburden ↓ Mura Unevenness ↓ Muda Waste You need to eliminate Muri first with KAIZEN to eliminate Muda. KAIZEN Categories -­‐ ECRS
• E • C • R • S Eliminate Combine Replace Simplify
Do you remember an Agile Principle?
Simplicity is EssenAal
The art of maximizing the amount of work not done
Do KAIZEN All The Time
•  Eliminate Muri •  Eliminate Mura •  Eliminate Muda And make your -­‐  Team -­‐  Process -­‐  Product -­‐  Company improve conAnuously Thank you. Let’s see how Kaizen works
Copyright© by Kojima Press Industory Co., Ltd
The Five S’s (5S)
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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
When do you have a strong moAvaAon for work? Survey in Japanese and U.S. automakers showed the same result. 1.  Autonomy 2.  Responsibility 3.  Achievement 4.  Opportunity 5.  The work itself 6.  Advancement 7.  RecogniAon
How can you use Lean / TPS
•  In your so{ware development? •  In your organizaAon? •  With your career?
Think Yourself In Your Context Because TPS stands for
Thinking People’s System Thank you
そこの障子を開けてみよ。外は広いぞ。 “Open the door, it’s a large world outside.” Sakichi Toyoda