Lean Operations In this module we will discuss the concepts behind Just-in-time or lean operations. The best implementation of these ideas is at Toyota (check Operations under About Toyota to know more about their U.S. operations) and is referred to as the Toyota production system. A basic discussion of the ideas behind lean operations is contained in Chapter 10 of the book (MBPF). Here are two articles on just-in-time by Taiichi Ohno and Shigeo Shingo, two architects of the Toyota production system. Also read a discussion by the authors of The Machine That Changed the World. The authors further expand their ideas to lean enterprises in an HBR article. A nice discussion of how JIT can be implemented in a pragmatic manner is given by Zipkin. Recently, some of the most innovative ideas in auto manufacturing have been implemented in Brazil. Read about the Volkswagen and GM implementations of lean manufacturing in Brazil . You can also have a virtual tour of a new Volkswagon plant or see a video on Ford's Plant. Other articles that may supplement the discussion in class include: At Toyota, a Global Giant Reaches for Agility, New York Times, February 2008. Microsoft changes how it builds software, Wall Street Journal, September 2005 Wall Street Journal on Lean production at Boeing and Airbus, picture (2005) Toyota Production system (2003) Pulling the chord at Toyota (2003) Economist on Toyota (2005) Cells in Furniture manufacturing (New York Times, 2005) Business 2.0 (March 2004) on flexible manufacturing at Ford Wall Street Journal (April 2004) article on lean manufacturing ideas applied to hospitals New York Times (August 2003) on increasing flexibility in auto assembly plants Wall Street Journal (June 2002) on lean operations and the economic recovery New York Times article (August 31, 2001) on lean operations at auto suppliers in the downturn Mercedes Production System (The Mercedes take on TPS) from the Automotive news. Wall Street Journal, March 15, 01 article on lean operations comparing Toyota and the U.S. auto manufacturers Financial Times, December 8, 00 on Build-to-order in the auto industry The Buffalo News, November 5, 00 on factories using lean manufacturing Aviation Week, Oct 30,00 on Boeing using the Toyota production System Lean operations at Boeing (1999) Information Week, July 17, 00 on a cycle manufacturer using lean manufacturing The Long, Long Wait for Cars, NYT May '00 on automakers trying to speed up response time for car orders New York Times article on Dell and Ford Motoring Lessons, Economist June '98 on lean production in the auto industry Toyota's Crusade; BUSINESS WEEK, April 7, 1997 Getting Control of Just-In-Time: HBR article from 1989 that discusses situations where JIT may and may not be appropriate. Compares proper application of JIT and MRP Some of the concerns about lean operations arediscussed in three articles about the fire at a Toyota supplier (1, 2, 3), an article about the problem with teams at Levi's, and an Economist article. Video Lean transformation at Dumore Corporation ("bit older" but shows the ideas well) Software Downloads Machsim-Processmodel.pdf Document detailing a simulation using PROCESS MODEL to see the impact of buffer sizes and variability on thruput. Files needed to run simulation (all three must be downloaded to the same folder):  Thruput.flo , Thruput.glb, Thruput.pmd EXCEL machine simulation:  machsim.xls shows the impact of buffer sizes and variability in throughput. Documnetation for the simulation is contained in Machsim-Excel.pdf The Dice Game (Internet Explorer Only): An interactive simulation of the matches game in The Goal on pp.104-105 that guides you through different questions and identifies key takeaways. Last Modified: 3/27/12