Dipl.-Ing.oec. Dennis Behnke, LSSMBB
Introduction to Lean Management
Lean Six Sigma Yellow Belt Course
The Automotive Industry: Trendsetter for Production Concepts and Technologies
The cradle of the ‘industry of industries’: Early automobiles were mostly custom-made in craftsmen's workshops.
Benz Patent-Motorwagen Nr. 1(Benz & Cie., Mannheim, Germany)
P2D (Daimler-licensed engine by Panhard & Levassor, Paris, France)
The First Revolution of the Automobile Industry and the Rise of the Big Three
After WW2, more than ¾ of the global automobile production was based in the United States.
Craft Production
- Interchangeability of parts- Moving assy line- Division of labor
Henry Ford (1863-1947)
Alfred Sloan (1875-1966)
Mass Production
The ‘Big Three’
1st Automobile Revolution
The Japanese Automobile Industry after WW2
After WW2, the Japanese automobile industry had but poor circumstances. Target: Many models in small quantities.
Diversified Consumer
Requirements Shortage of Capital and Resources
Dominance of US
ManufacturersConfident
Labor Force
Nagoya
The Decline of the US Automobile Industry and the Rise of Japanese Lean Production
From the 1960s onwards, the Japanese auto-industry gained market share, and Toyota became the leading global automobile manufacturer.
[WomackJones90]
The Second Revolution of the Automotive Industry Quantified
GM Framingham Toyota TakaokaGross assy hours per car 40.7 18.0Adj.* assy hours per car 31 16Assy defects per 100 cars 130 45Assy space per car 8.1 4.8Avg inventories of parts 2 w 2 h
*Only standard activities which were comparable in both plants[WomackJones90]
Japanese factories seem to produce cars in a shorter time, with lower costs,and a higher quality.
The Japanese Pioneers of Lean Production
豊田 英二とよだ・えいじ
Toyoda Eiji(1913-2013)
豊田佐吉とよだ・さきち
Toyoda Sakichi(1867-1930)
大野耐一おおの・たいいち
Ohno Taiichi(1912-1990)
Founder of Toyota GroupInventor of Jidoka textile looms
Launched Toyota’s automobile production,inventor of Just-in-Timeprinciple
Toyota Group executive,father of the Toyota Production System
豊田喜一郎とよだ・ きいちろう
Toyoda Kiichiro(1894-1952)
Long-term president and chairman of Toyota Group
新郷 重夫しんごう・しげお
Shingō Shigeo(1909-1990)
Engineer at Toyota, made several key contributions (Kaizen, SMED, …)