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Kaizen Methodology |
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Historical Background
1.The management of the technical background
After World War II, the Japanese auto industry to start, at this time to rule the world mode of production is represented by the Ford system of mass production methods. This mode of production lines is in large quantities and less variety of products to bring economies of scale to lower costs and thus bring about price competitiveness.
In particular: At the time, a large number of modes of production that is representative of the advanced management ideas and methods. A lot of special equipment, specialized high-volume production is to reduce costs and improve the competitiveness of the main mode. At the same time, a comprehensive quality control in the United States and other advanced industrialized countries have begun trying to promote, and embodiment in the practice of certain benefits. Production inventory control thinking (thinking mainly to MRPII) has also begun to put forward, but due to technical reasons, unable to move toward practical use.
2.Development of environmental background
When the United States in the development of the apex of the automobile industry, Japan's auto manufacturers can not be its mode of production in the same competition. At the end of the 40's to early 50's, the Japanese vehicle production is almost zero, while the United States is 5000000-7000000 around. Among them, Toyota Motor Corporation in 1950 from the establishment of more than a decade, the total output of even one day less than the output of Ford. At the same time, Japanese companies must also be faced with a lack of demand and the technology behind such serious difficulties, coupled with the post-war Japan, a serious shortage of funds; it is difficult to have large-scale capital investment to ensure that the automobile production in Japan reached the scale of competitive. In addition, Toyota Motor Corporation during a visit to the United States after several major automobile plant also found that corporate governance in the United States, particularly in personnel management, there is difficult to accept of the Japanese companies.
Therefore, the 20th century, the 50's to Toyota's first man-made resistance on behalf of Ono's 'lean production' of the founding fathers, in the form of analysis of the first mass production model of lean production to low-cost, high-quality and high efficiency to U.S. counterparts resulted in a huge threat. The mid-80's, the United States the brink of crisis, General Motors, and Toyota is the rapid development of the peer surprised. In the 80's, the theory of lean manufacturing to continuous development and improvement, and now, the production organization and management methods have been widely introduced the world's top 500, to implement.
In Toyota's lean manufacturing to create the same time, Japan has unique cultural atmosphere to promote the emergence of lean production. Japanese culture is a typical oriental culture, emphasis on collective and collaborative efforts in lean manufacturing for human management provides a new perspective of thinking. Meet the requirements of this pursuit of the collective consciousness and coordination of Eastern culture, is also in line with Japan's unique personnel management system.
Thus the situation at that time, Toyota Motor Corporation in the impossible, and unnecessary way of taking the road of mass production, according to the characteristics of their own, and gradually created a unique multi-species, low-volume, high-quality and low consumption in production.
3.The needs of production efficiency
From the 50's to 70's, although Toyota's unique mode of production has achieved remarkable success, but the Japanese and the Western economy has shown signs of rapid growth, even if the United States the same way high-volume production can be achieved the effect of large-scale production. Therefore, Toyota Production System during this period has not been a real attention only in the Toyota Motor Corporation and its complementary part of business enterprises in Japan to be implemented.
1973 oil crisis, Japan's auto industry has brought unprecedented opportunities, but also the entire Western economies slow into the growing darkness. Changing market environment, the high-volume production has become more and more obvious weaknesses, at the same time, Toyota's performance began to rise, automakers and other enterprises from growing, lean production by the beginning of the real world for the people of the world.
Lean production to the production of the invalidity of the labor and early access to the excess inventory is treated as a waste of labor. Put an end to such waste, which requires the removal of mercilessly not directly link to add value and jobs. In the production and supply of materials in the production strictly enforce the time, so by the time required and the required quantity, the relevant departments or positions to provide the materials needed, that is no intermediate stock is entirely demand-driven pull-type production.
The implementation of the most modern efficient and competitive production systems, the production cycle will be reduced 60-90%, 50-80% reduction in the products, the production efficiency of 10-100%, 30% waste reduction, job-related injury reduced by 50%.
With the growing price war, has become a lean manufacturing enterprise to increase market share and enhance the competitiveness of the key strategies.
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