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<h2 class="wp-block-heading has-medium-font-size">¿Qué es el Lean Manufacturing?</h2>



<p class="has-medium-font-size"><strong>Lean Manufacturing</strong> es un <strong>sistema de gestión de la producción</strong> (aunque el modelo ha sido aplicado y extendido a servicios, administración, mantenimiento etc.) <strong>adaptado de Toyota desde la década de 1950 en su metodología TPS &#8211; Toyota Production System</strong>.</p>



<figure class="wp-block-image size-large"><img src="https://leankaizen.net/wp-content/uploads/2022/06/Lean-00-Toyota-Production-System-House-1024x576.jpg" alt="método lean" class="wp-image-22"/></figure>



<p class="has-medium-font-size">El sistema Lean se centra en la <strong>eliminación del </strong><a href="https://leankaizen.net/muda/" target="_blank" rel="noreferrer noopener"><strong><em>muda</em></strong> </a>(término en japonés que significa <a href="https://leankaizen.net/los-7-desperdicios-del-lean-manufacturing/" target="_blank" rel="noreferrer noopener">desperdicio</a>, waste en inglés). Muda definida como toda actividad que absorbe recursos y no aporta valor.</p>



<p class="has-medium-font-size">Lean Manufacturing se basa en poner énfasis primero en <strong>entender las necesidades de los clientes </strong>(internos y externos) y trata de <strong>centrarse en aquellas actividades que aportan “<a href="https://leankaizen.net/lean-manufacturing/" target="_blank" rel="noreferrer noopener">Valor</a>” para el cliente</strong>. <strong>Busca la eliminación de los desperdicios</strong> mediante la identificación de los desperdicios y sus causas. Para hacer más con menos se deben diseñar acciones que incrementen el “Valor” percibido por el cliente.</p>



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<h2 class="wp-block-heading"><strong>Orígenes del Lean</strong> Management</h2>



<h3 class="wp-block-heading has-medium-font-size"><strong>1776 Watt</strong></h3>



<p class="has-medium-font-size">James Watt (Escocia) inicia la nueva era de la fabricación moderna con la invención de la máquina de vapor, y con ello, arranca la Revolución Industrial.</p>



<h3 class="wp-block-heading has-medium-font-size"><strong>1801 Whitney</strong></h3>



<p class="has-medium-font-size">Eli Whitney (USA) introduce la estandarización al producir piezas intercambiables en la fabricación de mosquetes, hecho que dio ímpetu a la fabricación en masa industrial.</p>



<h3 class="wp-block-heading has-medium-font-size"><strong>1856-1915 Taylor</strong></h3>



<p class="has-medium-font-size">Frederick Taylor (USA) cambia la forma de entender la fabricación al introducir el método científico promoviendo conceptos tácticos de fabricación por lotes y la división funcional del trabajo, así como la separación de la planificación de la ejecución de trabajos, medición de tiempos, especializar al trabajador en tareas sencillas y repetitivas, diseño de un sistema de primas por producción etc.</p>



<h3 class="wp-block-heading has-medium-font-size"><strong>1903 Ford</strong></h3>



<p class="has-medium-font-size">Henry Ford (1863-1947, USA) funda en Ford, en 1908 fabrica 15 millones de uds del modelo T solo en color negro. Revolucionó la industria al crear cadenas de montaje, pasando de fabricación artesanal en puesto fijo a cadena de montaje donde los suministros se aprovisionaban directamente en el puesto de trabajo, trabajadores que no se desplazaban con tareas muy específicas. Se logra reducir un 88% el tiempo de fabricación, con ello los costes de transformación y el precio de mercado, haciendo un producto asequible para la clase media.</p>



<h3 class="wp-block-heading has-medium-font-size"><strong>1924 Sakichi Toyoda</strong></h3>



<p class="has-medium-font-size">Sakichi Toyoda (1867-1930, Japón) inventor y filósofo desarrolla varios inventos, inventa telares sencillos, entre ellos incorpora un sistema que detiene los telares cuando se rompe un hilo, detiene la máquina y avisa al operario. Este invento se define como Jidhoka, autonomation, automatización con cero defectos y tuvo mucha popularidad entre la industria textil. Patenta su telar modelo G.</p>



<h3 class="wp-block-heading has-medium-font-size"><strong>1937 Kiichiro Toyoda y nacimiento de Toyota Motor Company</strong></h3>



<p class="has-medium-font-size">Nace el hijo, Kiichiro Toyoda, desarrolla una metodología para que los telares de su padre funcionen mucho tiempo sin interrupciones por avería. Vende la patente “a prueba de errores” a los hermanos Platt, visita la industria estadounidense de la que admira los avances en la industria automovilística y funda Toyota para competir con Ford y General Motors, que se asientan 5 años antes en Japón a partir de componentes estadounidenses.</p>



<p class="has-medium-font-size">Funda la Toyota Motor Company, con la primera fabricación del modelo de automóvil A1 y camión G1.</p>



<p class="has-medium-font-size">Se le atribuye el JIT (just in time) donde se fabrica lo que se necesita, en la cantidad justa, cuando se necesita y en la calidad correcta.</p>



<h3 class="wp-block-heading has-medium-font-size"><strong>1950 Eiiji Toyoda le sustituye</strong></h3>



<p class="has-medium-font-size">Posterior a la segunda guerra mundial, Toyota sufre una gran crisis financiera, debe recurrir a despidos masivos y se llegan a grandes acuerdos a nivel laboral con sus trabajadores. Kiichiro, avergonzado dimite.</p>



<p class="has-medium-font-size">El sobrino de kiichiro, Eiiji Toyoda  ;le sustituye al frente de Toyota hasta su dimisión en 1982 donde Toyota se convierte en tercera industria automotriz tras GM y Ford. Se alcanza un gran acuerdo con sindicatos que reforzará un nuevo rumbo de confianza a largo plazo con los trabajadores.</p>



<h3 class="wp-block-heading has-medium-font-size"><strong>1940-1950 Taiichi Ohno y Shigeo Shingo</strong></h3>



<p class="has-medium-font-size">En época de una gran crisis para Toyota Taiichi Ohno (Japón, 1912-1990) se las ingenió para implantar muchas mejoras con poca inversión. Escribió varios libros.</p>



<p class="has-medium-font-size">Por otro lado <a href="https://es.wikipedia.org/wiki/Shigeo_Shingo" target="_blank" rel="noreferrer noopener">Shigeo Shingo</a>(Japón, 1909-1990), maestro de <a href="https://es.wikipedia.org/wiki/Taiichi_Ohno" target="_blank" rel="noreferrer noopener">Taiichi Ohno</a> y un gran consultor industrial resolviendo problemas industriales de todo tipo. Entendió que la variabilidad (los muda, mura, muri) eran el enemigo de las operaciones y analizó el flujo continuo, la estandarización, el JIT, el SMED, poka yoke, … y escribió 14 libros.</p>



<h3 class="wp-block-heading has-medium-font-size"><strong>1987 Nacimiento del Lean y expansión </strong></h3>



<p class="has-medium-font-size">El término “Lean” fue creado en 1987 en el MIT, por un equipo de investigadores en el que se incluía James P. Womack y Daniel T. Jones, los cuales estaban estudiando el sistema de Toyota (TPS – Toyota Production System) analizando el diseño, la producción, el aprovisionamiento y el servicio con clientes.</p>



<p class="has-medium-font-size">Identificaron las <strong>diferencias de TOYOTA con el sistema tradicional</strong> de producción en masa de Ford y General Motors:</p>



<ul class="has-medium-font-size wp-block-list">
<li>Necesita menos recursos humanos para diseñar, fabricar y servir los productos.</li>



<li>Necesita un menor volumen de inversión para conseguir un volumen de capacidad productiva.</li>



<li>Fabrican productos con un menor nivel de defectivo y retrabajos.</li>



<li>Utilizan menos proveedores, pero más cualificados.</li>



<li>Pueden fabricar una mayor gama de productos con menor coste para mantener precios y ganar cuota de mercado.</li>



<li>Necesita menos nivel de inventario en cada fase del proceso.</li>
</ul>



<p class="has-medium-font-size">Analizando todos los elementos descritos y viendo que siempre se necesitaba menos de todo para crear una cantidad determinada de valor, los definieron como una <strong>organización “esbelta” (lean)</strong>. Por lo tanto, el “lean manufacturing” recoge las técnicas lean desarrolladas en el sistema de producción de Toyota.</p>



<figure class="wp-block-image size-large"><img src="https://leankaizen.net/wp-content/uploads/2022/06/Lean-02-Origenes-del-lean-1024x576.jpg" alt="metodo lean" class="wp-image-31"/></figure>



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