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Mar 26 2018

Visit to Honda’s Kumamoto Plant | Christoph Roser | All About Lean

Honda Goldwing

“The Honda Kumamoto plant was established in 1976 and is the largest Honda plant in Japan by area. It is their main plant for the production of motorcycles in Japan including their engines, but it also produces garden power tools, generators, and four-wheeled scooters.

A major earthquake in Kumamoto in April 2016 damaged the plant, and it reopened and scaled up production again during the summer of 2016. employees in the plant, 8% of them being women.”

Sourced from All About Lean

Michel Baudin‘s comments: Another insightful report from Christoph Roser’s “grand tour of Japanese factories.”

#Honda, #JapanFactoryVisits

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By Michel Baudin • Blog clippings • 0 • Tags: Honda, Japan Factory Visits

Mar 21 2018

The Battle for the Soul of Lean | Michael Ballé | The Lean Post

Michael Ballé: “I’ve been a student of lean for 25 years, and the more that I learn the more I believe that […] lean is a profoundly disruptive way of working. From the time that this new approach was popularized decades ago, there have been two completely different ways to look at the same tools, materials, and stories. Some of us saw Toyota as a disrupter, a small bankrupt company that became the dominant automaker in a saturated market ruled by U.S. corporate giants, by doing something radically different. Others, however, were fascinated by Toyota’s ‘operational excellence’ as a means of safe, incremental improvements—they would cherry-pick tools […] to leverage productivity gains without ever challenging either the strategy or the attitudes of top management.”

Sourced from The Lean Post

Michel Baudin‘s comments: I have been a student of TPS for 38 years, and see it as the best way we know today to make cars and auto parts. And, yes, it has been successfully adapted to other manufacturing industries and even to some service businesses. Lean is a marketing label coined 30 years ago that, in the best cases, has been used to describe TPS or adaptations of TPS in situations where explicit references to Toyota would be problematic, for example at Toyota competitors or in hospitals, where the last thing you want to do is convey the impression that you treat patients like cars. In the worst cases, consultants have slapped this label on approaches unrelated to TPS, just to leverage Toyota’s credibility.

Continue reading…

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By Michel Baudin • Blog clippings • 8 • Tags: HItozukuri, Lean, People development, Respect for Humanity, Toyota, TPS, Valeo

Mar 18 2018

Nissan Yokohama and Iwaki Plant Visits | Christoph Roser | All About Lean

 

Carlos Ghosn – Savior of Nissan

“Overall, Nissan automotive plants have an outstanding performance, comparable to Toyota despite their different approach using much more automation. I believe that Nissan plants are also among the world’s best automotive plants, besides (behind?) Toyota. I definitely enjoyed the visit (but then, I am a geek for such kind of things).”

 

 

Sourced from All About Lean

Michel Baudin‘s comments: Thanks again to Christoph Roser for sharing this. Reading this reminded me that, when he took over as Nissan CEO, Carlos Ghosn left the plants alone. They were doing fine. What needed fixing, he decided, was product design and the supply chain. History has since validated his choices.

#Nissan, #CarlosGhosn, #JapanPlantTour, #ShopFloor

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By Michel Baudin • Blog clippings • 3 • Tags: Carlos Ghosn, Japan plant tour, Nissan, Shop floor

Mar 18 2018

Honda Sayama Plant Visit | Christoph Roser | All About Lean

Honda’s 1st product

“Overall, I was not impressed by the Sayama plant. Part of it can be explained by its age, another part by it being closed in 2022 (and who wants to invest time in a plant that will be closed anyway), but there was still enough left over to make this a pretty unimpressive plant. I went away with a pretty bad impression of Honda plants. Luckily, Honda Kumamoto was much, much better. More about this in the next post.”

Sourced through AllAboutLean

Michel Baudin‘s comments: Thanks to Christoph Roser for his detailed trip reports from Japan!

#Honda, #SayamaPlant

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By Michel Baudin • Blog clippings • 0 • Tags: Honda, Sayama Plant

Mar 6 2018

Factory Of The Future | Daniela Costa | Goldman-Sachs

“The factory is getting a facelift, thanks to a raft of new technologies designed to make manufacturing more efficient, flexible and connected. Daniela Costa […] outlines three key drivers of this development, which could provide more than $500 billion in combined savings for manufacturers and customers.”

Source it from Goldman-Sachs

Michel Baudin‘s comments:

Thanks. I didn’t know Goldman-Sachs was the go-to place for manufacturing expertise.

The only departure from classical automation hype is the emphasis on human-machine collaboration. This topic had been ignored in the American and European approach to automation, with the exception of Working With Machines.

Otherwise, she used the word “significant” many times, probably to imply the existence of research and data behind her statements while saying nothing about what that research might have been. I am particularly curious about where the “$500B in savings” figure came from. It is given context-free, so we don’t know whether she means in Europe or worldwide and over how many years.

She also equated automation with the use of robots but that is common in the press.

#automation, #jidoka, #workingwithmachines, #robots

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By Michel Baudin • Blog clippings • 1 • Tags: Automation, jidoka, robots, Working with machines

Feb 26 2018

Re-Translating Lean from Its Origin | Jun Nakamuro | LinkedIn

“The world first became aware of TPS (The Toyota Production System) when Taiichi Ohno published a book about his groundbreaking efforts at Toyota. It was published in Japan in 1978. The Japanese version of his book wasn’t translated into English until 1988. Since ten years had passed, this translation did not fully communicate the nuances of Ohno’s vision. ”

Sourced from LinkedIn

Michel Baudin‘s comments: I have also argued for recovering the nuances of TPS that have been lost in translation, whether these losses are due to incompetence or obfuscation, in the following posts:

  • “Wisdom” and “Continuous Improvement” in the Toyota Way
  • Does Respect For Humanity Mean The Same As Respect For People?
  • “Muda” just means “Unnecessary”
  • More musings on “Muda” (Waste)
  • Absence of “Value Added” in the TPS literature
  • Perspectives on Standard Work

In his article, Nakamuro bemoans the “decades of confusion” caused by our collective failure to translate Taiichi Ohno’s thoughts accurately. According to him, Ohno frequently called different ideas or methods by names that sound identical but are written differently, which strikes me as a poor communication strategy, if your goal actually is to make yourself understood.

Continue reading…

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By Michel Baudin • Blog clippings • 0 • Tags: Current State Assessment, Muda, Ohno, Taiichi Ohno, Toyota Production System, TPS, Waste

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