What is Lean Ship Construction and Repair?

2002 ◽  
Vol 18 (03) ◽  
pp. 121-142
Author(s):  
Jeffrey K. Liker ◽  
Thomas Lamb
Keyword(s):  
Production System ◽  
Lean Manufacturing ◽  
Just In Time ◽  
Product Cycle ◽  
Time Cost ◽  
Toyota Production System ◽  
Case Examples ◽  
Cost Competitiveness ◽  
Automobile Manufacturer ◽  
System Project

The success of the Toyota Production System is well known. Toyota is the most productive and innovative automobile manufacturer in the world. Directly or indirectly they have pioneered approaches and principles such as, among many others, just in time, one-piece flow, and "andon." The Toyota Production System was the basis for "lean manufacturing." The purpose of lean manufacturing is to improve product cycle time, cost competitiveness, and quality by eliminating any waste in the manufacturing process through continuous improvement by a motivated workforce. The authors, as part of the NASSCO shipbuilding production system project, were responsible for introducing lean manufacturing to the project team and developing a "Guide to Lean Shipbuilding." This paper first discusses what lean manufacturing is, and then reports on a benchmarking visit to Japanese shipyards. Finally, a description of lean shipbuilding and its implementation is presented with case examples of lean workshops.

Lean production, Toyota Production System and Kaizen philosophy

2018 ◽  
Vol 30 (4) ◽  
pp. 425-438 ◽  
Author(s):  
Andrea Chiarini ◽  
Claudio Baccarani ◽  
Vittorio Mascherpa
Keyword(s):  
Production System ◽  
Zen Buddhism ◽  
Management Style ◽  
Japanese Culture ◽  
Just In Time ◽  
Toyota Production System ◽  
Lean Implementation ◽  
Content Type ◽  
Lessons Learnt ◽  
Soto Zen

Purpose The purpose of this paper is to compare principles from the original Toyota Production System (TPS), the Toyota Way 2001 and Kaizen philosophy with principles derived from Japanese Zen Buddhism. The paper would also like to enlarge the debate concerning some lessons learnt from Japanese culture in order to avoid Lean implementation failures. Design/methodology/approach The original English version of Taiichi Ohno’s book dedicated to the TPS, the Toyota Way 2001 and other relevant papers regarding Kaizen were reviewed and analyzed. The principles that emerged from the review of this literature were then compared with similar philosophical principles from Japanese Soto Zen Buddhism. The literature concerning Zen philosophy was methodically analyzed and categorized using the content analysis. Findings The results of this research show many theoretical parallelisms as well as lessons for practitioners, in particular referring to principles such as Jidoka, just-in-time, waste identification and elimination, challenge, Kaizen, Genchi Genbutsu, respect for people and teamwork. Research limitations/implications Analysis and results are mainly based on the literature that was found, reviewed and categorized, along with the knowledge of authors on Zen philosophy. Results could differ depending on the literature reviewed and categorized. Practical implications The results of this research bring food for thought to practitioners in terms of lessons learnt from Japanese culture, Toyota principles and management style in order to avoid Lean implementation failures. Originality/value This is one of the first papers which compares Lean-TPS and Kaizen principles with the Zen philosophy to try to learn lessons for succeeding in Lean implementation.

DEMONSTRATIVE VERIFICATION STUDY FOR THE NEXT GENERATION PRODUCTION MODEL: APPLICATION OF THE ADVANCED TOYOTA PRODUCTION SYSTEM

2008 ◽  
Vol 07 (02) ◽  
pp. 195-219 ◽  
Author(s):  
HIROHISA SAKAI ◽  
KAKURO AMASAKA
Keyword(s):  
Production System ◽  
Production Management ◽  
Production Model ◽  
Just In Time ◽  
Toyota Production System ◽  
Global Business ◽  
Production Management System ◽  
Japanese Companies ◽  
Advanced Production ◽  
System Methodology

Traditional TPS (Toyota Production System), the foundation of JIT (Just in Time), has contributed to global business in the latter half of the 20th century as a Japanese production management system methodology. At present, Japanese companies are endeavoring to survive in a competitive market by expanding their global production, achieving globally consistent levels of quality, and carrying out simultaneous new model launches. An advanced production management principle, "Advanced TPS", has been proposed, involving the systematization of Japanese production management methodologies as a strategic tool for global production. The effectiveness of the proposed "Advanced TPS" was verified at Toyota Motor Corporation.

Streamlined from the Start

2006 ◽  
Vol 128 (03) ◽  
pp. 30-32 ◽  
Author(s):  
Scott Miller ◽  
James Richmond ◽  
Aron Bowman
Keyword(s):  
Product Development ◽  
Production Process ◽  
Production System ◽  
Lean Manufacturing ◽  
Manufacturing Industry ◽  
Development Process ◽  
Toyota Production System ◽  
Lean Product Development ◽  
Innovative Products

This article discusses the importance of lean product development in the manufacturing industry. Lean manufacturing is a concept developed by Toyota more than 30 years ago. It was motivated by the desire to build better and more innovative products with lower costs. The result was the evolution of what is commonly known as the Toyota production system. This system increases efficiency and reduces waste in each area of the production process by eliminating unnecessary efforts and empowering all levels of the workforce. Lean product development is based on the theory of lean manufacturing. The processes focus on simplicity and effectiveness. Lean product development allows for communication between multi-departmental teams, simplifying and keeping the development process moving forward. Using lean product development to manage projects puts accountability on the project owners.

Application of Pull Concept-based Lean Production System in the Ship Building Industry

2013 ◽  
Vol 29 (03) ◽  
pp. 105-116
Author(s):  
Khairul Hassan ◽  
Hiroyuki Kajiwara
Keyword(s):  
Production System ◽  
Lean Manufacturing ◽  
Simulation Analysis ◽  
Lean Production ◽  
Just In Time ◽  
Optimization Analysis ◽  
Basic Principles ◽  
Pull Production ◽  
Scheduling Method ◽  
Pull Production System

Shipbuilding is a convoluted process. The production system of a shipyard can be illustrated by using the concept of a pull production system. Lean is based on the principle of a pull production system. The shipbuilding process is improved significantly but the lean production system is introduced at very small scales. In a shipyard, different types of wastages such as scraps, overproductions, idle times, etc. are produced, lean is a just-in-time production system that can focus on the elimination of these wastages to ensure lower costs and lower production times and higher quality products as well as better service and delivery. Simulation modeling is used to evaluate the performance of the production system and kanban is a pull-type scheduling method that can be used to simulate the pull production system of a shipyard for the optimization analysis. The goals of this article are to identify the important wastages in a shipyard that can increase production time and cost, to design the production system of a shipyard based on lean philosophy, to derive the basic principles of the lean manufacturing as well as to develop the control mechanism of this production system, the simulation analysis of the production system done by using the lean principle, and to identify the limitations for applying the lean production system in a shipyard production.

scholarly journals A REVIEWOF LEANAPPLICATION IN MANUFACTURING ENVIRONMENT: DEFINITIONS AND TERMINOLOGIES

2019 ◽  
Vol 14 (Number 2) ◽  
pp. 28-45
Author(s):  
Azim Azuan Osman ◽  
Abdul Aziz Othman ◽  
Mohd Kamarul Irwan Abdul Rahim
Keyword(s):  
Production System ◽  
Lean Manufacturing ◽  
Lean Production ◽  
Toyota Production System ◽  
Asian Countries ◽  
Manufacturing Environment ◽  
Clear Insight ◽  
The Subject

This articleis a review of definitions and terminologies used in existing literatures related to application of Lean Systemin manufacturing environment. The article is made to provide clear insight and comparisons on various terms used incontemporary academicjournals, booksand published theseson the subject of Lean System.This review realizes that the term Lean Manufacturing was more popular among Malaysian and Asian countries, while Lean Production was mostly used by American scholars. From this review, readers also might learn that Lean System and Toyota Production System are not really the same system due to a missing principle. The presentreview is concluded with visual explanation regarding several major jargons in Lean System.

scholarly journals LEAN MANUFACTURING APPLIED TO COLLECTIVE FOOD KITCHENS LEAN KITCHEN

2020 ◽  
pp. 34613-34618
Keyword(s):  
Production System ◽  
Lean Manufacturing ◽  
Toyota Production System ◽  
Check List ◽  
Problem Identification ◽  
Application Problem ◽  
Efficiency And Effectiveness ◽  
Increase Productivity ◽  
Information Collections

The Lean Kitchen is based on the Japanese TPS (Toyota Production System) system that increases productivity, efficiency and effectiveness within the kitchens. One of the principles of this philosophy is to identify the problem, optimizing resources to reduce waste, that is, lean manufacturing, in terms of eliminating bottlenecks and gaps. This article brings the theme of Lean Kitchen, to increase productivity, efficiency and effectiveness within the kitchens, as well as the concept of value, in terms of how much the customer is willing to pay. Therefore, the objective is to apply the lean concept within its outsourced industrial restaurants. Restaurants respond to variations in demands and varieties of service, however, as in any process, there are several problems that need to be meticulously detected in order to heal them. Literature based on Lean philosophy and the case study and metrics were used, such as: Visit to the Gemba reports; information collections; check-list application; problem identification; Brainstorming (team and leadership); Dynamics of engagement with team and leadership; visual communication application, feedback schedule with customers; Tools (5s; Pareto, Ishikawa, 5W2H; PDCA).

Applying Lean Above the Factory Floor

2002 ◽  
Vol 18 (03) ◽  
pp. 159-166
Author(s):  
John D. Drogosz
Keyword(s):  
Production System ◽  
Business Processes ◽  
Shop Floor ◽  
Lead Times ◽  
Improve Quality ◽  
Toyota Production System ◽  
Shipbuilding Industry ◽  
Case Examples ◽  
Kaizen Events ◽  
Factory Floor

Modern Kaizen events have been based on the principles of the Toyota Production System (TPS). However, TPS is a system used in repetitive manufacturing and not typically associated with business processes. The goal of TPS is to eliminate waste in order to improve quality, shorten lead times and reduce costs. Clearly this same philosophy applies as much above the shop floor as it does in the factory. This paper first discusses how to adapt the lean philosophy and Kaizen methodology to business processes above the shop floor. It will also present some case examples from lean workshops conducted in the shipbuilding industry.

Some Aspects of Lean Manufacturing

2012 ◽  
Vol 488-489 ◽  
pp. 1142-1146
Author(s):  
Ajai Kumar Pathak
Keyword(s):  
Production System ◽  
Lean Manufacturing ◽  
Lead Time ◽  
Single Unit ◽  
Point Of View ◽  
Team Work ◽  
Just In Time ◽  
Pull System ◽  
Floor Space ◽  
Individual Effort

Lean manufacturing production system considers the expenditure for any goals other than the creation of value for the end customer to be wasteful. Only operation adds value to the product and other functions such as inspection, transportation, and delays of a permanent or temporary nature are waste and should be eliminated. The beginning of lean manufacturing can be seen in Just In Time (JIT). It was first implemented in Ford automobile in the form of line assembly. Lean manufacturing is based on pull system. In the pull system parts are produced when they are pulled by the process before that. Lean manufacturing defines the value of a product or a service with the customer point of view not on the basis of type of technology and amount of labour. In the lean manufacturing the organization is treated as a single unit. Team work is more important than individual effort. The implementation of lean manufacturing reduces lead time, reduces work in progress (WIP), saves floor space, increases productivity, improves quality and reduces overall cost. In this paper various aspects of lean manufacturing have been examined and discussed.

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