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1990
                                                                                                                                                                                                                                                                                                                                                                                                                                        1930s                                                                                                                                                                                                                                                                                                                The Machine That
                                                                                                                                   1860s                                                                                                                                                                                                                                                                                                Takt Time                                                                                                                                                     1965
Breakthrough Moments in Lean                                                                                                       High-Volume                                                                                                                                          The Model T                                                                                                                                     German aircraft-industry pioneers use takt
                                                                                                                                                                                                                                                                                                                                                                                                                                        time as a way to synchronize the movement
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      Mass Production                                                                                                 1987
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                             Changed the World
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                             Jim Womack, Dan Jones, and
                                                                                                                                   Interchangeable Parts                                                                                                                                                                                                                                                                                of aircraft in assembly operations in which                                                                                                                   Management                                                                                                      “Lean” Introduced                      Daniel Roos write an explanation
                                                                                                                                   Samuel Colt’s Armory in Hartford, CT,                                                                                                                                                                                                                                                                each major section or complete airframe                                                                                                                       Alfred Sloan publishes My Years      1977                                  1982                                                                        of the fulfillment, product design,
                                                                                                                                   claims to produce pistols in large volumes                                                  1890s                                                                                                                                                                                                    needs to move to the next assembly station                                                                                                                    with General Motors to fully         First Dissemination                   Full Description
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      John Krafcik, a young
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                             supplier management, customer
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                       researcher in the MIT
                                                                                       1780s                                       with completely interchangeable parts.                                                      Scientific Management                                                                                                                                                                                    at the same time. A precise takt time means                                                                                                                   describe the manage-by-metrics
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                           of TPS                                of TPS                               International Motor Vehicle
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                             support, and global management
                                                                                                                                   Later investigation by David Hounshell                                                      Frederick Taylor analyzes work in search                                                         1924                                         1926                                                                                                                                                                                                                                                                                                                                                                            system pioneered by the best
                                                                                       Concept of                                                                                                                                                                                                                                                                                                                                       that the cycle time for the work at each                       1950s                                                                                          system he developed at General
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                           Fujio Cho, Y. Sugimori, and           Yasuhiro Monden’s Toyota             Program, proposes a label
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                             Japanese companies and provide
                                                                                       Interchangeable Parts
                                                                                                                                   (1984) shows that the parts were only                                                       of the one best way to do every job. He adds
                                                                                                                                                                                                                                                                                  1908                                          Quick Changeovers                            Mass Production                                            station must be precisely                                      Kanban and Supermarkets                                       1960                             Motors from the 1920s into the
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                           others at Toyota publish the          Production System is translated      for the combination of
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                             exhaustive evidence of the
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                             2005
                                                                                                                                   interchangeable for special weapons                                                         a piece-rate bonus system, “scientifically”                                                                                                                                                                                                                                                                                                                            1950s. This is just as Toyota
                                                                                       French Army Ordinance pioneers                                                                                                                                                             Truly Interchangeable Parts                   The G-type loom at Toyoda Automatic          As Henry Ford completes his vast Rouge complex he          analyzed to keep it below                                      Taichi Ohno develops practical methods                        Deming Prize                                                          first article in English—in a         into English and published in        production, product
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                             competitive superiority of the                                                                  Lean Solutions
                                                                                       the concept of interchangeable parts
                                                                                                                                   created for sales promotions. Pistols in                                                    setting wages to spur effort and tying
                                                                                                                                                                                                                                                                                  Henry Ford introduces a modular car and       Loom Works introduces a zero-time            adds product variety and introduces the term “mass         the takt time. Mitsubishi                                      to implement Kiichiro Toyoda’s concept                        Japanese Union of Scientists
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      emerges in world markets to
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                           UK engineering journal—               the U.S. by the Institute of         development, supplier
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                             complete system.
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  1997                                       Jim Womack and Dan Jones apply
                                                                                                                                   regular production still had “fitted”                                                       complex production paths together by                                                                                                                                                                                                                                                                                                                                   become GM’s rival.
                               1500s Flow Production                                   for weapons, a necessary precursor          parts requiring extensive manual labor.                                                     means of a clearly documented travel               makes a great leap in interchangeable parts   shuttle changeover so the loom can           production.” While the flow of materials at the Rouge is   has a technical relation                                       for just-in-time delivery of parts.                           and Engineers inaugurates the                                         explaining the logic of the           Industrial Engineers, providing      collaboration, customer                                                                     Lean Enterprise Institute                  the process thinking at the heart of
                               Venetian Arsenal introduces floating assembly           to high-volume, flow production.                                                                                                                                                                                                         keep running continuously. This idea         automated by miles of conveyors, the complex locates       with the German aircraft                                                                                                                                                                           Toyota Production System.             the first description of the         support, quality, and                                                                       Jim Womack creates a non-profit,           lean thinking to consumption (what
                                                                                                                                   The problem of fabricating truly                                                            path through a factory for every part. He          through a standard gauging system used                                                                                                                                                                                                                                             Deming Prize to encourage
                               line for boats of standard designs moving through                                                                                                                                                                                                                                                leads eventually to quick changeovers        different types of fabrication steps (e.g., stamping,      industry and brings the                                                                                                                                                                                                                  entire Toyota Production             management methods                                                                          education, publishing, and research        the consumer does to solve his or her
                                                                                                                                   interchangeable metal parts without                                                         also introduces standard cost accounting           throughout his plant and by every supplier.                                                                                                                                                                                                                                        Japanese companies to
                               standard assembly stations. First example of flow                                                                                                                                                                                                                                                in every piece of equipment at the           welding, paint) in “process villages,” and most final      idea back to Japan where                                                                                                                                                                                                                 System to a global audience.         pioneered by Toyota.                                                                        organization to promote lean               problems) and to provision (the steps
                                                                                                                                   extensive “fitting” continues to baffle                                                     to allocate overheads to machine and labor         Ford announces, “There are no files in                                                                                                                                                                                                                                             embrace statistical quality
                               in history?                                                                                                                                                                                                                                                                                      Toyota Motor Company.                        assembly is moved to as many as 50 final assembly          Toyota embraces it.                                                                                                                                                                                                                                                                                                                                                       principles and deepen understanding        provider organizations must take to
                                                                                                                                   industrialists for another 50 years.                                                        hours, creating the basic management               my factory.”                                                                                                                                                                                                                                                                       control and Plan-Do-Check-Act.
                                                                                                                                                                                                                                                                                                                                                                             plants around the world.                                                                                                                                                                                                                                                                                                                                                                                                             of lean ideas and methods.                 help solve consumer problems).
                                                                                                                                                                                                                               tools of mass production.

                                                                                                                                                                                Colt’s Armory, Hartford, CT



                                              1500s                                           1700s                                             1800s                                                                                             1900s                                                                              1920s                                                                                   1930s                                                                                  1950s                       1960s                                                                     1970s                                                       1980s                                                  1990s                                                                                               2000s


                                                                                                               1799                                                                       1880s                                       1902                                                                                                                                                                                                                                                                                                                                                                                                                                               1983                                                                                                                                 1998                                 2007
                                                                                                               Automatic Production                                                       Moving Disassembly Line                     Jidoka                                        1913 –1914                                                                                                                                                                                                                                                                                                                                                                                           Direct Diffusion                                                                                                                     Learning to See                      Lean Global Network
                                                                                                               of Simple Parts
                                                                                                                                                                                          American meat packers in the Midwest        Sakichi Toyoda invents a device to detect     Moving Assembly                                                                                                                                                                                                                                                                                                                                                                                      Toyota agrees to a joint-venture                                                                                                     Mike Rother and John Shook           Organizations around the world
                                                                                                                                                                                          introduce conveyors to steadily move        broken threads in looms, automatically        Line with Parts                                                                                                                                                                                                                                                                                                                                                                                      factory with General Motors                                                                                                          introduce Toyota’s concept of        promoting lean thinking through
                                                                                                               Marc Brunel devises water-powered                                          carcasses past the workers who remove       stopping production of defective cloth.                                                                                                                                                                                                      1941–1945                                                                                                                                  1973                                                       —New United Motors
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                               Late 1980s                                       1996                                          material and information flow        publications, education, and
                                                                                                               equipment for the Royal Navy in England                                    the meat from the bone. A provocative       With additional refinements, this permits     Fabrication                                                                                                                                                                                    Training Within Industry                         1960s                                                                                     Codifying TPS                                              Manufacturing (NUMMI)—                Widespread Diffusion                             Lean Thinking                                 diagrams, now called value-stream    research join forces in a new,
                                                                                                               that can make simple parts like rope                                                                                                                                 Henry Ford’s Highland Park plant
                                                                                                               blocks for ships with no manual labor.
                                                                                                                                                                                          example to later innovators who tackled     machines to operate without the need
                                                                                                                                                                                                                                                                                    pioneers “flow production” by
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                   The U.S. Dept. of War introduces job             Lean Management                                                                           Fujio Cho, Y. Sugimori,                                    near San Francisco to directly        A host of writers (Robert Hall,                  Jim Womack and Dan Jones provide              maps, to a broad audience.           non-profit organization to promote
                                                                                                                                                                                          the much more difficult task of             for workers (often children) to watch                                                                                                                                                                                                        instruction, job methods, job relations,         Under the leadership of Eiji Toyoda,                                                      and others create the                                      transfer TPS outside of the           Richard Schonberger, Norman                      a simple description of lean principles                                            lean concepts more effectively.
                                                                                                                                                                                          moving assembly.                            each machine and uncouples workers            placing fabrication equipment                                                                                                                                                                  and program development as ways to                                                                                                         first Toyota Production                                    Japanese environment.                 Bodek) and consultants                           —value, value stream, flow, pull,
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    the Toyota Motor Company gradually
                                                                                                                                                                                                                                      from machines to permit multimachine          in process sequence (e.g., a                                                                                                                                                                   teach millions of workers in war industries.     creates a management system with                                                          manual for internal use.        1979                                                             (former members of the Toyota                    and perfection—along with stories
                                                                                                                                                1822                                                                                  operation by a single worker.                 stamping press next to a paint                                                                                                                                                                 These methods were introduced in Japan           a new approach to problem solving,                                                                                        First Academic                                                   Autonomous Study Group such                      of companies beyond Toyota that
                                                                                                                                                Automatic Production                                                                                                                booth next to a final assembly                                                                                                                      1937                                       at the end of the war and were eventually        leadership, production operations,
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    1965                                                                      Investigations                                                   as Yoshiki Iwata and Chihiro                     are applying them successfully                                                     2007
                                                                                                                                                of Complex Parts
                                                                                                                                                                                                                                                                                    area for a single part number)
                                                                                                                                                                                                                                                                                                                                                                                                                                        Just-in-Time                               incorporated in Toyota’s thinking about          supplier collaboration, product and             Quality as a Key Element                                                  MIT launches the Future
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                               Nakao) promote lean methods                      in North America, Europe, and
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                   Lean as No. 1
                                                                                                                                                                                                                                                                                    and operating the whole                                                                                                                                                                        standard work.                                                                                                                                                                                                                              far beyond the Japanese                          Japan. The final section presents
                                                                                                                                                Thomas Blanchard at the Springfield                                                                                                 factory at the rate of the
                                                                                                                                                                                                                                                                                                                                                                                                                                        As Kiichiro Toyoda establishes the                                                          process development, and customer               of a Management System                                                    of the Automobile Program
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                               auto industry.                                   an action plan for any company
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                   For the first time Toyota passes
                                                                                                                                                Armory in the U.S. devises 14 machines to                                                                                                                                                                                                                                               Toyota Motor Company he has the                                                             support.                                        Toyota wins the Deming Prize after a                                      (which became the International                                                                                                                                                                      General Motors to become the
                                                                                                                                                                                                                                                                                    final assembly line.                                                                                                                                                                                                                                                                                                                                                                                                                                                                        to follow toward a lean
                                                                                                                                                progressively make gun stocks for rifles                                                                                                                                                                                                                                                idea for just-in-time delivery of parts.                                                                                                    multiyear campaign to teach every                                         Motor Vehicle Program in 1985)                                                                                                                                                                       world’s largest motor vehicle
                                                                                                                                                                                                                                                                                                                                                                                                                                        A lack of basic stability in production                                                                                                     manager how to solve problems using                                                                                                                                                         transformation.
                                                                                                                                                with no manual labor. The parts are moved                                                                                                                                                                                                                                                                                                                                                                                                                                                                     to study new methods of designing                                                                                                                                                                    producer and moves ahead as the
                                                                                                                                                from machine to machine around a room.                                                                                                                                                                                                                                                  and in supplier relations thwarts                                                                                                           a scientific method based on W. Edwards                                   and producing products in Japan.                                                                                                                                                                     world’s most consistently successful
                                                                                                                                                The first instance of cellular production?                                                                                                                                                                                                                                              actual implementation.                                                                                                                      Deming’s Plan-Do-Check-Act cycle.                                                                                                                                                                                                                                              commercial organization of
                                                                                                                                                                                                                                                                                                                                                      Highland Park Ford Plant, Highland Park, Michigan                                                                                                                                                                                                                                                                                                                                                                                                                                                            the preceding 50 years.
                               From View of the Entrance to the Arsenal by Canaletto

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Lean Breakthrough Timeline

  • 1. 1990 1930s The Machine That 1860s Takt Time 1965 Breakthrough Moments in Lean High-Volume The Model T German aircraft-industry pioneers use takt time as a way to synchronize the movement Mass Production 1987 Changed the World Jim Womack, Dan Jones, and Interchangeable Parts of aircraft in assembly operations in which Management “Lean” Introduced Daniel Roos write an explanation Samuel Colt’s Armory in Hartford, CT, each major section or complete airframe Alfred Sloan publishes My Years 1977 1982 of the fulfillment, product design, claims to produce pistols in large volumes 1890s needs to move to the next assembly station with General Motors to fully First Dissemination Full Description John Krafcik, a young supplier management, customer researcher in the MIT 1780s with completely interchangeable parts. Scientific Management at the same time. A precise takt time means describe the manage-by-metrics of TPS of TPS International Motor Vehicle support, and global management Later investigation by David Hounshell Frederick Taylor analyzes work in search 1924 1926 system pioneered by the best Concept of that the cycle time for the work at each 1950s system he developed at General Fujio Cho, Y. Sugimori, and Yasuhiro Monden’s Toyota Program, proposes a label Japanese companies and provide Interchangeable Parts (1984) shows that the parts were only of the one best way to do every job. He adds 1908 Quick Changeovers Mass Production station must be precisely Kanban and Supermarkets 1960 Motors from the 1920s into the others at Toyota publish the Production System is translated for the combination of exhaustive evidence of the 2005 interchangeable for special weapons a piece-rate bonus system, “scientifically” 1950s. This is just as Toyota French Army Ordinance pioneers Truly Interchangeable Parts The G-type loom at Toyoda Automatic As Henry Ford completes his vast Rouge complex he analyzed to keep it below Taichi Ohno develops practical methods Deming Prize first article in English—in a into English and published in production, product competitive superiority of the Lean Solutions the concept of interchangeable parts created for sales promotions. Pistols in setting wages to spur effort and tying Henry Ford introduces a modular car and Loom Works introduces a zero-time adds product variety and introduces the term “mass the takt time. Mitsubishi to implement Kiichiro Toyoda’s concept Japanese Union of Scientists emerges in world markets to UK engineering journal— the U.S. by the Institute of development, supplier complete system. 1997 Jim Womack and Dan Jones apply regular production still had “fitted” complex production paths together by become GM’s rival. 1500s Flow Production for weapons, a necessary precursor parts requiring extensive manual labor. means of a clearly documented travel makes a great leap in interchangeable parts shuttle changeover so the loom can production.” While the flow of materials at the Rouge is has a technical relation for just-in-time delivery of parts. and Engineers inaugurates the explaining the logic of the Industrial Engineers, providing collaboration, customer Lean Enterprise Institute the process thinking at the heart of Venetian Arsenal introduces floating assembly to high-volume, flow production. keep running continuously. This idea automated by miles of conveyors, the complex locates with the German aircraft Toyota Production System. the first description of the support, quality, and Jim Womack creates a non-profit, lean thinking to consumption (what The problem of fabricating truly path through a factory for every part. He through a standard gauging system used Deming Prize to encourage line for boats of standard designs moving through leads eventually to quick changeovers different types of fabrication steps (e.g., stamping, industry and brings the entire Toyota Production management methods education, publishing, and research the consumer does to solve his or her interchangeable metal parts without also introduces standard cost accounting throughout his plant and by every supplier. Japanese companies to standard assembly stations. First example of flow in every piece of equipment at the welding, paint) in “process villages,” and most final idea back to Japan where System to a global audience. pioneered by Toyota. organization to promote lean problems) and to provision (the steps extensive “fitting” continues to baffle to allocate overheads to machine and labor Ford announces, “There are no files in embrace statistical quality in history? Toyota Motor Company. assembly is moved to as many as 50 final assembly Toyota embraces it. principles and deepen understanding provider organizations must take to industrialists for another 50 years. hours, creating the basic management my factory.” control and Plan-Do-Check-Act. plants around the world. of lean ideas and methods. help solve consumer problems). tools of mass production. Colt’s Armory, Hartford, CT 1500s 1700s 1800s 1900s 1920s 1930s 1950s 1960s 1970s 1980s 1990s 2000s 1799 1880s 1902 1983 1998 2007 Automatic Production Moving Disassembly Line Jidoka 1913 –1914 Direct Diffusion Learning to See Lean Global Network of Simple Parts American meat packers in the Midwest Sakichi Toyoda invents a device to detect Moving Assembly Toyota agrees to a joint-venture Mike Rother and John Shook Organizations around the world introduce conveyors to steadily move broken threads in looms, automatically Line with Parts factory with General Motors introduce Toyota’s concept of promoting lean thinking through Marc Brunel devises water-powered carcasses past the workers who remove stopping production of defective cloth. 1941–1945 1973 —New United Motors Late 1980s 1996 material and information flow publications, education, and equipment for the Royal Navy in England the meat from the bone. A provocative With additional refinements, this permits Fabrication Training Within Industry 1960s Codifying TPS Manufacturing (NUMMI)— Widespread Diffusion Lean Thinking diagrams, now called value-stream research join forces in a new, that can make simple parts like rope Henry Ford’s Highland Park plant blocks for ships with no manual labor. example to later innovators who tackled machines to operate without the need pioneers “flow production” by The U.S. Dept. of War introduces job Lean Management Fujio Cho, Y. Sugimori, near San Francisco to directly A host of writers (Robert Hall, Jim Womack and Dan Jones provide maps, to a broad audience. non-profit organization to promote the much more difficult task of for workers (often children) to watch instruction, job methods, job relations, Under the leadership of Eiji Toyoda, and others create the transfer TPS outside of the Richard Schonberger, Norman a simple description of lean principles lean concepts more effectively. moving assembly. each machine and uncouples workers placing fabrication equipment and program development as ways to first Toyota Production Japanese environment. Bodek) and consultants —value, value stream, flow, pull, the Toyota Motor Company gradually from machines to permit multimachine in process sequence (e.g., a teach millions of workers in war industries. creates a management system with manual for internal use. 1979 (former members of the Toyota and perfection—along with stories 1822 operation by a single worker. stamping press next to a paint These methods were introduced in Japan a new approach to problem solving, First Academic Autonomous Study Group such of companies beyond Toyota that Automatic Production booth next to a final assembly 1937 at the end of the war and were eventually leadership, production operations, 1965 Investigations as Yoshiki Iwata and Chihiro are applying them successfully 2007 of Complex Parts area for a single part number) Just-in-Time incorporated in Toyota’s thinking about supplier collaboration, product and Quality as a Key Element MIT launches the Future Nakao) promote lean methods in North America, Europe, and Lean as No. 1 and operating the whole standard work. far beyond the Japanese Japan. The final section presents Thomas Blanchard at the Springfield factory at the rate of the As Kiichiro Toyoda establishes the process development, and customer of a Management System of the Automobile Program auto industry. an action plan for any company For the first time Toyota passes Armory in the U.S. devises 14 machines to Toyota Motor Company he has the support. Toyota wins the Deming Prize after a (which became the International General Motors to become the final assembly line. to follow toward a lean progressively make gun stocks for rifles idea for just-in-time delivery of parts. multiyear campaign to teach every Motor Vehicle Program in 1985) world’s largest motor vehicle A lack of basic stability in production manager how to solve problems using transformation. with no manual labor. The parts are moved to study new methods of designing producer and moves ahead as the from machine to machine around a room. and in supplier relations thwarts a scientific method based on W. Edwards and producing products in Japan. world’s most consistently successful The first instance of cellular production? actual implementation. Deming’s Plan-Do-Check-Act cycle. commercial organization of Highland Park Ford Plant, Highland Park, Michigan the preceding 50 years. From View of the Entrance to the Arsenal by Canaletto