This document provides a biography and overview of Shigeo Shingo, a Japanese industrial engineer known for developing key Lean Manufacturing techniques. It describes that he was born in 1909 in Japan, worked in various manufacturing roles, and consulted globally. It outlines some of his most important contributions, including developing Just-In-Time production and Single Minute Exchange of Dies methods in the 1950s-1970s to reduce waste and changeover times. It also discusses his development of poka-yoke/mistake proofing approaches to eliminate defects. Shingo played a pivotal role in the development of modern Lean principles still used around the world today before his death in 1990.

1. Prepared by:
Aliasgar Mandsaurwala – 15
Heeral Seth -
新郷重
夫

2.  Born in 1909 at Saga City, Japan.
 Graduated from Yamanashi Technical College (1930); worked for the Taipei
Railway Company.
 Worked in Amano Manufacturing Plant, Yokohama (1945).
 Developed Just-In-Time(JIT) and Toyota Production System (1959).
 Reduced setup time of hull assembly on a 65,000-ton super tanker from 4
months to 2 months - a new record in shipbuilding. (1956-1958)
 Developed the ‘Defects=0’/ poka-yoke/ mistake proofing(1961).
 “Single Minute Exchange of Dies” concept. (1970)
 Died in 1990.
Overview
A relentless barrage of ‘why’s‘ is the best way to prepare your mind to
pierce the clouded veil of thinking caused by the status quo. Use it
often.

3.  International consultant to some of the world’s largest companies
such as: Toyota, Bridgestone, Peugeot, AT&T.
 His most impactful techniques are as follows :
 Just In Time (JIT)/TPS.
 Single Minute Exchange of Dies (SMED).
 Zero Quality Control/Poka-yoke.
Key Techniques
The best approach is to dig out and eliminate
problems where they are assumed not to exist

4.  Just in time (JIT) is a production strategy that strives to improve a business’
return on investment by reducing in-process inventory and associated
carrying costs.
 Primary objective : obtain a competitive advantage and increased
productivity by eliminating the following seven types of wastes:
 Waste from overproduction
 Excess Transportation
 Excess Inventory
 Waiting Time
 Processing Waste
 Wasted Motion
 Waste from Production Defects
Just-In-Time
Improvement usually means doing something that
we have never done before.

5.  Developed in order to reduce the fixed cost associated with the setup and
changeover of dies.
 Reduce the setup time of dies, which directly result in smaller batch sizes
for parts.
 Allows manufacturing system to quickly adjust to engineering design
changes with very little costs.
 Allows for higher machine utilization and in turn results in higher
productivity.
Single Minute Exchange of Dies
Those who are not dissatisfied will never
make any progress

6.  To isolate and identify the setup time as two entities: internal setup time
and external setup time.
 a simple approach to achieving a quick setup and changeover of the dies :
 Separating internal and external setup as it is existing.
 Converting internal to external setup.
 Streamlining all aspects of the setup operation.
Single Minute Exchange of Dies
It’s only the last turn of a bolt that tightens it
– the rest is just movement

7.  100 percent inspections done at the source instead of sampling inspections.
 Immediate feedback from successive quality checks and self checks.
 Poka-yoke designed manufacturing devices.
 basic idea was to implement mistake-proofing devices in the assembly line.
 Targeting the root cause of defect (source defect) whenever a defect occurs.
Zero Quality Control
Lean is a way of thinking – not a list of things
to do