Japanese Manufacturing Techniques Nine Hidden Lessons in Simplicity

272 Pages·1982·7.964 MB·English

by  Richard J. Schonberger

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THE FREEP RESS
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A DivisoifMo anc milPluabnl isChoi.nI,gn c.
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NEW YORK
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ColliMearc millPaunb lishers
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1982 J.
Copyri©g ht byR ichardS chonberger
Allr ighrtess ervNeod p.a rotf t hibso ok mbaeyr eproduocre d
transmiitnta endyf ormo rb ya nym eanse,l ectroonrmi ecc hanical,
includpihnogt ocopyriencgo,r dionrbg y,a nyi nformatsitoonr age
andr etriesvyaslt ewmi,t hopuetr missiinwo rni tifnrgo mt heP ublisher.
TheF reeP ress
A DivisioofMn a cmillPaunb lishCion.gI, n c.
866 10022
ThirAdv enueN,e w YorkN,. Y.
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ColliMearc millCaann adaI,n c.
Printientd h eU niteSdt atoefsA merica
printniunmgb er
2 3 64 7 598 1 0
LibroafrC yo ngrCeatsasl ogiinPn ugb licDaattiao n
;v;z:
SchonbergReirc,h arJd.
Japanese manufatcetcuhrniinqgu es.
Bibliograpp.h y:
Includiensd ex.
l.I ndustrmiaanla gement Ja2p.aP nr.o duction
managemenIt..T itle.
HD70.J3S361 982 658.5'00952 82-48495
ISBN0 -02-929100-3
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Preface
VII
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Acknowlgemdents
XI
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• Chapt1e. rI ndustMrainaalg emeinnJt a paann dt heW orld 1
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LESSO1N: Managementte chnoliosag h yi ghly
transporctoambmloed ity.
Chapt2.e rj ustT-iimne-P roductwiiotTnho tal Quality 15
Control
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' --l LESSO2N: Just-in-ptriomdeu cteixopno ses
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probleomtsh erwhiisded ebnye xcess
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Chapt3.e rT otaQlu aliCtoyn trol 47 '
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LESSO3N: Qualibteyg iwnist phr oduction,
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andr equirace osm pany-w"ihdaeb oift
improvement.''
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Chapt4.e rT heD ebuotfJ ustT-iimne-P roductiinto hne 83
UnitSetda tes
LESSO4N: Cultuirsne o o bstactleec;h niques
canc hangbee havior.
Chapter
5. PlanCto nfigurations 103
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LESSO5N: Simpliafnydg, o odwsi lfllo wl ike
water.
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6. ProductionM-aLniangee ment 131
LESSO6N: Flexibiolpietndyso ors.
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' Chapt7.e rju stT-iimne-P ucrhasing 157
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LESSON T7:r avelli gahntd m aken umerous
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tripsl ikteh ew atebre etle.
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Contents
Chapt8.e rQ ualiCtiyr clWeosr,kI mprovemeanntd, 1 81
Specialization
LESSO8N: Mores elf-iomvpermenfte,w er
programlse,ss sp eciailnitsetr vention.
Chapt9.e rP rosepctfso Cra tchiUnpg 199
LESSO9N: Simpliciistt hyen atursatla te.
AppendiTxh:eK anbaSnys tem 219
239
Notes
247
Bibliaopghry
252
Index
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Some seteobm e lietvheaw te n owk now tahlelri est ok now
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abouJta paneisned ustmrainaalg emepnrto,d uctiavnidqt uya,l ­
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ityt;h awte h avrea ketdh Jea panessyes teomv etrh ec oalasn d
carefuelxlaym intehdea sheTsh.e triustt hha tth eW es·hta s
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hardbleyg unu ntdoe rstJaanpda nseuscec efsasc toarnsdm, u ch
ofw haits p rofesisnce udr rerneta dicnognss iosfth sa lf-truths
andm isconceptthiaostnt sa nidnt hew ayo fr apipdr ogriens s
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catchuipnw gi tthh eJ apaneAsseM .c Gilnlo tetsh,ep opular
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bookasb ouJta panmeasnea gem(eanltte atshtr heaev bee ebnest­
selle"rhsa)vl ei tttols ea ya boulti fient hec orportarteen ches.
Theimre ssacgoem efsr oamn di sa ddrestsoeC dE Os[ chieexf-
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whatm]a nageirnts h mei ddlaer"te o d o1.
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Thibso ok dweiatlwhsh amta nageirnts h mei ddalrete o d o '
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. arer elevtaon tt moapn ageArnsd.t heriesa goodde atlos ay:
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i ninlee ssoinnss i mplicittyh,ce e enatctrhoa ploi fco nef uclhla p-
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agemenptr escriptoiuoro:r:t bss esswiiotnhp rogramwsi,t h
controwlistc,ho mputaenrdsi nformaptrioocne sswiintgbh,e ­
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havioirnatle rvenatnidwo intsmh,a thematmiocdaell iInngs.t ead
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thep robleAmm.o ngt hes implifiTeoryso,ti ast hes tandard­
beareTrh.es impbluet i ngeniporuosd uctmiaonna gemeanntd
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qualciotnyt raoplp roacdheevse lobpye dT oyaontdoa t hleera d-
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inmga nufactsuereemtr ost ravel teoao stihleJyra panefisrem s
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withorueta lly beingJ atpaaungebhsutes iinsnec shso oolrps r o-
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motebdy c onsultants.
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Ib elietvhaett h aep proacthreasv el teooa tshielry countries
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i asw ellT.h ei nhergeonotd s ensoef t het echniqaunedas p -
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Preface
proacthheesm selvest hfeomisortb eirlsAi ntdyt .h eirsep relimi­
nareyv idenfcreo,mJ apanessueb sidioapreireast inUg.S .o n
shoretsh,aJ ta panpersoed ucatnidoq nu almiatnya gemweonrtk s
inn on-Japasneetstei Wnigtsah.p ologtioe sJ acBqrueeJisa, p a­
nessey steamrsea livaend w elaln do peratiintn hge U nited
States.
Rootosft hjea paneSsyes tem
Thes ystoefmp roducatnidoq nu almiatnya gemtehnattt h Jea pa­
neshea vdee velohpaescd u lturroaoltT sh.a its J,a panessoec ial
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behavitoernadle ncwiheisca,hr per oduocftt hsu en iqJuaep anese
environmheanvtae,c commodadteevde lopmoefhn itg helfyf ec­
tivper oductsiyosnt eBmust.t hsey stetmhse mselves ocfo nsist
simpplreo ceduarnedts e chniqmuoessot,f w hicdho n orte quire
ap ar�iceunlvairr onomrec nutl turalf ostreh tetiiimrnp gl ementa­
tio(nT.h roughhiosuttgo oroyid d etahsa hta vsep rufnogr th from
ag iveno fsc eitr cumsthaanvcbeee se and opteelds ewhaesr ef ast
as twhoer cdo ulsdp rde.)a
TheS ysteMma'isnC oncerns
TheJ apanessyes tecmo nsiesstsse ntoifat lwloty y pesp roofc e­
(1)
dureasn dt echniqTuhees .tt wyop epse rttaoi:n productivity;
(2)
qualiTthyea. s peocftt heJ apanessyes tedme alimnogs dti ­
just-in-time system.
rectwliytp hr oductiiskv niotwyan s t he Just­
in-tdiimree catdldyr estshemesa teriaclo mcpoosntoe fnp tr oduc­
tiviTthyei. n direefcfte acrteesv emno rep ronounacfefde,c ting
elemeonftp sr oductfirvoismtc yr atpow orkmeort ivattoip orno ­
cesysi elJda.p aneqsuea liimtpyr ovemiespn atr tiaadldlrye ssed
byj ust-inb-uttti hmeer,ae r ea hosotf o theJra paneqsuea lity
improvemceonntc epatnsdp roceduarswe esl Al .t ertmh aits
ofteuns eidn J apatnod escrtihbee osfeJ ta paneqsuea liimt­y
totqaula lciotnyt rol,
provempernotc eduirse s whicihnt urenn -
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compassseosm eo ft hej ust-int-etcihmnei qaunedis m,p roves
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producttihvriotuaygv ho idaonfwc aes tIen. other words,just-in­
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. ' timaen dt otqaula lciotnyt orvoelr laanpdt, h ewyi lblei ntroduced
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togetihnea rne arly chianpw theirct,hh eciern trali ntr hoel e
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Japanesster atoefgm ya rkedto minanicsde e monstrSaetpead-.
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chaptsehroswh ows imptleec hniqbueegsem to reo ft he. same, ·-. -
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encompasmsoisntgo ft hem anufactuernivnigr onmpelnatn:t
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configuratdieovnesl,o pmaenndt careeq uoifp memn(ltt,e rial
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shipasn,ds upplrieelra tionships.
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concernpirnogd uctainvdiq tuya liitmyp rovemaernent u rtured
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iarietsh eUi nni tSetda theosw,e vefirn,dt hemselwvietsh man­
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ageransd p rofessieodnuaclasit nes dp ecialistA-moerriiecnatne d
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colleagnedsm ,o shta vper ior expaesrs ipeencciea ilnit srtasd i­
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objectiavnedts h uosv ercotmhece h ioebfs tatcoml aek inJga p-
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neww orlodfm anagemiednetai nst hibso okS.o meo ft hied eas
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Preface
thahta vbee esnp readiinnNog r th Amehraivdceoa n seo i na bout
thes amew ays tthhaestyp reiandJ apaanm:o ntgh leo wearn d
middmlaen ageJruss.t -inh-atbsie meaenh otto paittc h epirro fes­
Implementa­
sionaasls ociamteieotni ingnts h pea st yoersa or.
tion
oft hesied eahass n otm adem uchp rogreasnsdc annaost
lonagsu ppemra nagearnsdt heciorn sultaanndat dsv isreermsa in
..
uninforambeodut th peo weorfJ apanjeusset -inp-rtoidmuec tion
andt otqaula lictoyn trTohle.p urposoefts h ibso oka ret o be
broadilnyf ormaatswi evlaels t os hohwo wt hsey stceamnb ep ut
inteof feacttt h oep eratlienvge l.
Becauismep lementhaatsbi eoenn silnot wh,ib so okIw ill
sometimbeeus n abltoec itpel anitnst hicso unttrhya t have
adoptae pda rticeulleamreo nftt h eJ apanessyes tebme indgi s­
cussebdu ti t oirtsla ym attoefrt imbee fotrhei wsi lclh ange.
We willle aarnnd w ew ililm plement thoeft hsJeya sptaenme se,
becautshee pirro ductainodqn u alpirtoyc eduretsh bea ersietn
thweo rlTdh.e A mericsayns tweams t hset andoafre dx cellence
ina p revieoruasa, n do thceoru ntriinecsl,u dJaipnagsn t,u diietd
andu seidt T.h ew orldc'osu ntrlieeasr n froomt heeiarnca h
never-encdyicnlAgen .di th'esa lthy.
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