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History<br />

16<br />

At the end of 1890, Frederick W Taylor<br />

became the first to study work management<br />

scientifically and distribute the results.<br />

His work led to the formalization of time<br />

and motion studies and the setting of<br />

common standards.<br />

Frank Gilbreth then added the concept of<br />

breaking work down into elementary time<br />

blocks.<br />

It was around this time that the first notions<br />

of eliminating waste and studying movement<br />

began to emerge.<br />

In 1910, Henry Ford invented the assembly<br />

line for his standardized Ford Model T.<br />

Alfred P. Sloan improved on Ford’s system<br />

when he introduced the concept of assembly<br />

line diversity at GM.<br />

After the Second World War, Taiichi Ohno<br />

and Shingeo Shingo created the “Just In<br />

Time”, “Waste Reduction” and “Pull System”<br />

concepts for Toyota, which, together with<br />

other flow management techniques, resulted<br />

in the Toyota Production System (TPS).<br />

The TPS has been evolved and improved ever<br />

since.<br />

In 1990, James Womack summarized these<br />

concepts to create Lean Manufacturing at a<br />

time when Japanese expertise was spreading<br />

to the West and the success achieved by<br />

companies applying these principles and<br />

techniques became undeniable.<br />

The Lean Manufacturing house can only grow<br />

if its foundations are built first.<br />

Without using a highly flexible and modular<br />

system that allows muda to be eliminated and<br />

Kaizen attitudes to be introduced into the<br />

plant, it is impossible to proceed to the later<br />

Standardize<br />

work<br />

The 7 mudas<br />

Lean Manufacturing identifies<br />

7 areas of waste or «muda».<br />

steps of Lean Manufacturing, which are work<br />

standardization, sequencing (Heijunka) JIT and<br />

JIDOKA. The systematic use of LeanTek ® acts<br />

as a catalyst for the policy of waste reduction<br />

and as a tool for implementing the Kaizen<br />

attitudes of continuous improvement.<br />

Muda caused<br />

by unnecessary<br />

stock<br />

Muda caused by<br />

overproduction<br />

KAIZEN<br />

Muda caused by<br />

defects/rejects<br />

Muda caused<br />

by unnecessary<br />

movement<br />

Muda caused<br />

Muda caused by<br />

by transport<br />

inappropriate<br />

processing<br />

Muda caused<br />

by waiting<br />

Progress<br />

17

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