Professional Documents
Culture Documents
Lean Production
Lean Production
willingness to change
German industrial survey
Markus P. Rler, Daniel Spiertz and Joachim Metternich
Table of contents
Table of contents
1. ..... Introduction
1.1.
Background
1.2.
Target group and survey details
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Version: 2014/04/28
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1. Introduction
1.1. Background
The Massachusetts Institute of Technology led a global benchmark analysis within the automotive industry in
the late 1980s. The results showed significant differences in the organization of production between Western
and Japanese companies. For these differences one of the researchers involved, John Kraftcik, distinguished
between lean and buffered production systems. In addition to the fact that Japanese car builders met higher
quality standards, also productivity and flexibility were significantly higher in these companies. Against a
growing competitive pressure from globalization and short product life cycles due to technical progress a
flexible production organization is increasingly important to still remain competitive. Therefore the first main
question of this article is, how nowadays industry has responded to the results of the mentioned study and set
up structured holistic production systems.
Taiichi Ohno, the designer of the Toyota production system, had to cope with the resistance of employees
during the introduction of lean production at Toyota. It took about ten years until lean production was
implemented at Toyota. This was because existing resistances had to be dismantled and overcome and to
achieve a complete reorganization of production. Ohno emphasized the importance of the involvement and
training of all workers for a successful implementation. Already this example shows, the willingness to change
of the staff involved is very important for success of the implementation of lean concepts. This raises the
second major question of this survey whether and to what extent producing companies are ready and open for
change.
The aim of this article is to provide an overview about both dimensions, the degree of penetration of lean
methods and the willingness to change in the field of production.
30
25
25
25
22
Number of answers
Number of answers
25
20
15
11
10
5
20
17
15
10
10
1
0
0
11 - 50
51 - 250
251 - 500
>500
Low volume
High volume
25
22
20
15
10
5
0
< 30 years
> 60 years
39
40
20
Number of answers
Number of answers
50 - 59 years
45
20
14
10
40 - 49 years
15
30 - 39 years
35
30
25
20
15
10
10
5
0
0
< 1 year
2 - 5 years
6 - 15 years
> 15 years
< 10 people
10 - 30 people
> 30 people
2.2. Relevance
The initial question of the survey served primarily to pin the scope of the survey and to arouse interest. In the
initial question subjects were asked to estimate whether lean production is a suitable approach to help
companies gain a competitive advantage over competitors, see therefore Figure 7. 89 percent (84 answers) of
all 95 respondents believe that competitive advantages can be gained by implementing lean methods. Another
five percent (6 answers) do not know whether competitive advantages can be achieved, and about three
percent (5 answers) do not believe in gaining competitive advantage through the implementation of lean
methods.
6%
5%
Yes
No
Not sure
89%
Figure 7: Methods of lean production as suitable tools to help companies to gain a competitive advantage over
competitors (n = 95 companies)
The concept of TPM (total productive maintenance) is used for service and upkeeping
18
Preventive maintenance exists in the complete plant with dynamic maintenance intervals
The current maintenance system helps to reduce scrap and rework effectively
6
0%
23
23
14
21
17
20
20
19
20%
20
21
15
10
18
14
10%
18
25
17
11
17
22
16
12
22
16
degree of agreement
low
medium
strong
17
20
10
The current maintenance system reduces standstills and performance losses effectively
25
10
12
very low
10
31
30%
40%
very strong
50%
60%
Number of answers
12
70%
80%
90%
100%
22
SMED (single minute exchange of die) is used for improving changeover times
37
degree of agreement
low
medium
strong
20
0%
10%
20%
30%
11
15
very strong
15
14
45
With the used methods significant improvements could be achieved in the past
very low
20
19
40%
50%
60%
Number of answers
18
70%
80%
6
90%
100%
In the whole production system target times for execution of activities are determined
17
14
17
10
15
23
13
11
42
21
Determined target times are communicated and visualized on the shop floor
0%
10%
12
20%
30%
11
11
20
33
degree of agreement
low
medium
strong
14
12
very low
36
12
16
14
40%
3 1
19
18
26
50%
60%
Number of answers
very strong
70%
80%
90%
100%
very low
degree of agreement
low
medium
strong
11
0%
10%
20%
20
30%
40%
very strong
20
50%
60%
Number of answers
11
70%
80%
90%
100%
17
19
19
System variability is taken into account by the implementation of value stream designs
15
Material flow simulations are used for planning and improvement of the production system
10%
13
12
18
40%
50%
60%
Number of answers
10
21
14
30%
13
11
20
14
19
20%
16
15
25
0%
13
15
18
18
23
With the method of value stream mapping significant improvements have been made
very strong
14
16
17
degree of agreement
low
medium
strong
23
13
very low
14
10
10
14
70%
11
80%
4
90%
100%
Figure 12: Results in the category production system and systematical improvement
5
20
Warehousing, storage and retrieval in production takes place using mainly supermarket and FIFO (first in
first out) principles
The production is organized in the form of flow production or single/one piece flow
The provision of materials is organized in the form of cyclic running transports (milkrun principle)
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Fluctuations in material demand are compensated by flexible transport capacity and flexible staff
planning
very low
degree of agreement
low
medium
strong
29
14
0%
10%
20%
30%
40%
very strong
11
18
12
10
18
10
22
10
14
14
13
19
16
18
18
17
23
18
10
15
12
19
11
22
50%
60%
Number of answers
70%
80%
90%
100%
Downtime, reasons for downtime and machine-related data are collected with a MES
14
Operating data is regularly evaluated and used for systematical improvement of the machine/plant
Machine data is regularly evaluated and used for systematical improvement of the machine/plant
Operating and machine data as well as recommendations are communicated to the shop floor staff
very low
degree of agreement
low
medium
strong
0%
10%
20%
30%
14
14
19
15
10
19
21
13
17
15
13
25
13
10
25
14
11
40%
very strong
50%
60%
Number of answers
70%
80%
90%
100%
The KPI (key performance indicator) utilization ratio is levied throughout the production
10
6
0%
25
10
13
7
10%
18
13
12
13
12
15
32
13
20
18
14
degree of agreement
low
medium
strong
16
11
29
10
15
very low
30%
16
15
14
20%
15
21
40%
very strong
50%
60%
Number of answers
13
70%
80%
90%
100%
Figure 15: Results in the category performance and shop floor management
Workers have standard procedures and rules for order and cleanliness at the workplace
very low
degree of agreement
low
medium
strong
5
0%
10%
very strong
30%
10
25
15
20%
22
17
24
16
12
16
15
16
20
17
17
25
13
10
40%
50%
60%
Number of answers
70%
80%
90%
100%
2.3.10.Visual management
Figure 17 presents the results of the category visual management. The category was answered by 61
respondents. Visual aids and control systems for displaying relevant information and to create transparency
exist in about 80 percent of companies surveyed, at least partially.
In production areas there are visual control systems to show relevant information and create
transparency
Status of production facilities and processes are presented transparent and are visualized
10
Shelves for material, manufacturing equipment and tools are explicitly defined and separated from
walkways
degree of agreement
low
medium
strong
16
25
25
15
15
15
0%
16
12
Material flow through all production areas is clearly defined and made visible
very low
17
18
6
10%
22
22
20%
30%
18
40%
50%
60%
Number of answers
very strong
70%
80%
90%
100%
19
Standard operating procedures are developed jointly by workers and job preparation department
19
13
0%
10%
20%
10
17
18
15
8
30%
14
12
very strong
14
16
14
degree of agreement
low
medium
strong
14
very low
13
10
15
14
13
22
15
19
12
40%
50%
60%
Number of answers
70%
80%
90%
100%
There are information tools that inform the staff about the latest developments within the company
2 1
degree of agreement
low
medium
strong
16
30
23
10
0%
28
19
26
29
There is a regular exchange in the company to discuss necessary / possible changes / improvements
19
25
very low
10
10%
22
28
20%
30%
40%
very strong
18
50%
60%
Number of answers
70%
80%
90%
100%
Figure 19: Results in the category communication and transparency in the corporation
degree of agreement
low
medium
strong
24
very low
11
5
0%
27
22
10
10%
22
25
20%
30%
40%
very strong
20
50%
60%
Number of answers
70%
80%
90%
100%
Figure 20: Results in the category decision making and management culture
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I have individual target agreements which are aligned to the departmental and corporate goals
very low
degree of agreement
low
medium
strong
12
1
0%
very strong
31
15
29
16
36
14
38
17
4
10%
20%
25
10
13
30%
40%
50%
60%
Number of answers
70%
80%
90%
100%
Figure 21: Results in the category personal assessment of the company and the production system
14
16
12
Number of answers
Number of answers
14
10
8
<= 250 employees
6
12
10
6
4
2
0
0
< 10
11 - 50
51 - 250
< 1,000
> 250
1 k - 10 k
> 10,000
A further question, whether employees receive a bonus if their proposal is implemented, was answered by
43 managers. 34 managers (79 percent) confirmed that their employees receive a bonus, 9 managers
(21 percent), however, denied the payment of a bonus in the event of a successful implementation of a proposal.
In 83 percent (49 responses) of surveyed companies a regular (e.g. annual) training of staff exists. 17 percent
(10 responses) of the participants denied a regular training of employees.
46 managers, representing a share of 77 percent, responded positively to the question of whether their
company has taken advice from consultancies for change or improvement of processes in the past three years.
15 participants (23 percent) said no to this question. How often such a service was taken into advantage
during the same period is plotted in Figure 24.
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Number of answers
12
10
8
<= 250 employees
6
4
2
0
Once
Twice
Figure 24: Quantity of in-house projects supported by consulting firms in the years 2011-2013 (n = 46 companies)
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2,71
2,82
2,13
2,06
2,27
2,17
2,06
1,69
1,19
2,42
2,21
2,12
2,26
2,12
1,94
2,05
1,84
1,84
1,85
1,88
2,98
2,54
2,55
2,51
2,59
2,72
1,25
2,05
1,65
1,9
1,79
1,88
2,05
1,69
1,84
1,71
1,94
2
1,24
1,52
1,49
1,58
0,94
0
SME
Large enterprises
0,5
With ESS
1,5
Without ESS
2,5
3,5
Figure 25: Clustered results in the section production system and systematical improvement (SME: n = 26; Large
enterprises: n = 33; Low volume / single piece production: n = 35; High volume production: n = 17; With ESS: n = 45;
Without ESS: n = 16 companies)
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