Lean Breakthrough Timeline


Published on

Timeline of Breakthrough Moments in Lean from flow production at the Venetian Arsenale in the 1500s to today.

You can see a larger online version at LEI site:

1 Comment
1 Like
No Downloads
Total views
On SlideShare
From Embeds
Number of Embeds
Embeds 0
No embeds

No notes for slide

Lean Breakthrough Timeline

  1. 1. 1990 1930s The Machine That 1860s Takt Time 1965 Breakthrough Moments in Lean High-Volume The Model T German aircraft-industry pioneers use takt time as a way to synchronize the movement Mass Production 1987 Changed the World Jim Womack, Dan Jones, and Interchangeable Parts of aircraft in assembly operations in which Management “Lean” Introduced Daniel Roos write an explanation Samuel Colt’s Armory in Hartford, CT, each major section or complete airframe Alfred Sloan publishes My Years 1977 1982 of the fulfillment, product design, claims to produce pistols in large volumes 1890s needs to move to the next assembly station with General Motors to fully First Dissemination Full Description John Krafcik, a young supplier management, customer researcher in the MIT 1780s with completely interchangeable parts. Scientific Management at the same time. A precise takt time means describe the manage-by-metrics of TPS of TPS International Motor Vehicle support, and global management Later investigation by David Hounshell Frederick Taylor analyzes work in search 1924 1926 system pioneered by the best Concept of that the cycle time for the work at each 1950s system he developed at General Fujio Cho, Y. Sugimori, and Yasuhiro Monden’s Toyota Program, proposes a label Japanese companies and provide Interchangeable Parts (1984) shows that the parts were only of the one best way to do every job. He adds 1908 Quick Changeovers Mass Production station must be precisely Kanban and Supermarkets 1960 Motors from the 1920s into the others at Toyota publish the Production System is translated for the combination of exhaustive evidence of the 2005 interchangeable for special weapons a piece-rate bonus system, “scientifically” 1950s. This is just as Toyota French Army Ordinance pioneers Truly Interchangeable Parts The G-type loom at Toyoda Automatic As Henry Ford completes his vast Rouge complex he analyzed to keep it below Taichi Ohno develops practical methods Deming Prize first article in English—in a into English and published in production, product competitive superiority of the Lean Solutions the concept of interchangeable parts created for sales promotions. Pistols in setting wages to spur effort and tying Henry Ford introduces a modular car and Loom Works introduces a zero-time adds product variety and introduces the term “mass the takt time. Mitsubishi to implement Kiichiro Toyoda’s concept Japanese Union of Scientists emerges in world markets to UK engineering journal— the U.S. by the Institute of development, supplier complete system. 1997 Jim Womack and Dan Jones apply regular production still had “fitted” complex production paths together by become GM’s rival. 1500s Flow Production for weapons, a necessary precursor parts requiring extensive manual labor. means of a clearly documented travel makes a great leap in interchangeable parts shuttle changeover so the loom can production.” While the flow of materials at the Rouge is has a technical relation for just-in-time delivery of parts. and Engineers inaugurates the explaining the logic of the Industrial Engineers, providing collaboration, customer Lean Enterprise Institute the process thinking at the heart of Venetian Arsenal introduces floating assembly to high-volume, flow production. keep running continuously. This idea automated by miles of conveyors, the complex locates with the German aircraft Toyota Production System. the first description of the support, quality, and Jim Womack creates a non-profit, lean thinking to consumption (what The problem of fabricating truly path through a factory for every part. He through a standard gauging system used Deming Prize to encourage line for boats of standard designs moving through leads eventually to quick changeovers different types of fabrication steps (e.g., stamping, industry and brings the entire Toyota Production management methods education, publishing, and research the consumer does to solve his or her interchangeable metal parts without also introduces standard cost accounting throughout his plant and by every supplier. Japanese companies to standard assembly stations. First example of flow in every piece of equipment at the welding, paint) in “process villages,” and most final idea back to Japan where System to a global audience. pioneered by Toyota. organization to promote lean problems) and to provision (the steps extensive “fitting” continues to baffle to allocate overheads to machine and labor Ford announces, “There are no files in embrace statistical quality in history? Toyota Motor Company. assembly is moved to as many as 50 final assembly Toyota embraces it. principles and deepen understanding provider organizations must take to industrialists for another 50 years. hours, creating the basic management my factory.” control and Plan-Do-Check-Act. plants around the world. of lean ideas and methods. help solve consumer problems). tools of mass production. Colt’s Armory, Hartford, CT 1500s 1700s 1800s 1900s 1920s 1930s 1950s 1960s 1970s 1980s 1990s 2000s 1799 1880s 1902 1983 1998 2007 Automatic Production Moving Disassembly Line Jidoka 1913 –1914 Direct Diffusion Learning to See Lean Global Network of Simple Parts American meat packers in the Midwest Sakichi Toyoda invents a device to detect Moving Assembly Toyota agrees to a joint-venture Mike Rother and John Shook Organizations around the world introduce conveyors to steadily move broken threads in looms, automatically Line with Parts factory with General Motors introduce Toyota’s concept of promoting lean thinking through Marc Brunel devises water-powered carcasses past the workers who remove stopping production of defective cloth. 1941–1945 1973 —New United Motors Late 1980s 1996 material and information flow publications, education, and equipment for the Royal Navy in England the meat from the bone. A provocative With additional refinements, this permits Fabrication Training Within Industry 1960s Codifying TPS Manufacturing (NUMMI)— Widespread Diffusion Lean Thinking diagrams, now called value-stream research join forces in a new, that can make simple parts like rope Henry Ford’s Highland Park plant blocks for ships with no manual labor. example to later innovators who tackled machines to operate without the need pioneers “flow production” by The U.S. Dept. of War introduces job Lean Management Fujio Cho, Y. Sugimori, near San Francisco to directly A host of writers (Robert Hall, Jim Womack and Dan Jones provide maps, to a broad audience. non-profit organization to promote the much more difficult task of for workers (often children) to watch instruction, job methods, job relations, Under the leadership of Eiji Toyoda, and others create the transfer TPS outside of the Richard Schonberger, Norman a simple description of lean principles lean concepts more effectively. moving assembly. each machine and uncouples workers placing fabrication equipment and program development as ways to first Toyota Production Japanese environment. Bodek) and consultants —value, value stream, flow, pull, the Toyota Motor Company gradually from machines to permit multimachine in process sequence (e.g., a teach millions of workers in war industries. creates a management system with manual for internal use. 1979 (former members of the Toyota and perfection—along with stories 1822 operation by a single worker. stamping press next to a paint These methods were introduced in Japan a new approach to problem solving, First Academic Autonomous Study Group such of companies beyond Toyota that Automatic Production booth next to a final assembly 1937 at the end of the war and were eventually leadership, production operations, 1965 Investigations as Yoshiki Iwata and Chihiro are applying them successfully 2007 of Complex Parts area for a single part number) Just-in-Time incorporated in Toyota’s thinking about supplier collaboration, product and Quality as a Key Element MIT launches the Future Nakao) promote lean methods in North America, Europe, and Lean as No. 1 and operating the whole standard work. far beyond the Japanese Japan. The final section presents Thomas Blanchard at the Springfield factory at the rate of the As Kiichiro Toyoda establishes the process development, and customer of a Management System of the Automobile Program auto industry. an action plan for any company For the first time Toyota passes Armory in the U.S. devises 14 machines to Toyota Motor Company he has the support. Toyota wins the Deming Prize after a (which became the International General Motors to become the final assembly line. to follow toward a lean progressively make gun stocks for rifles idea for just-in-time delivery of parts. multiyear campaign to teach every Motor Vehicle Program in 1985) world’s largest motor vehicle A lack of basic stability in production manager how to solve problems using transformation. with no manual labor. The parts are moved to study new methods of designing producer and moves ahead as the from machine to machine around a room. and in supplier relations thwarts a scientific method based on W. Edwards and producing products in Japan. world’s most consistently successful The first instance of cellular production? actual implementation. Deming’s Plan-Do-Check-Act cycle. commercial organization of Highland Park Ford Plant, Highland Park, Michigan the preceding 50 years. From View of the Entrance to the Arsenal by Canaletto