The history of Lean traces back to the early 20th century and has evolved significantly over decades. Henry Ford pioneered mass production techniques in the 1910s, introducing the assembly line concept that reduced waste and improved efficiency in automobile manufacturing. However, Ford's system la…The history of Lean traces back to the early 20th century and has evolved significantly over decades. Henry Ford pioneered mass production techniques in the 1910s, introducing the assembly line concept that reduced waste and improved efficiency in automobile manufacturing. However, Ford's system lacked flexibility for product variations.
The true foundation of Lean emerged in post-World War II Japan at Toyota Motor Corporation. Facing resource constraints and a devastated economy, Toyota engineers Taiichi Ohno and Shigeo Shingo developed the Toyota Production System (TPS) between 1948 and 1975. They studied American supermarkets and adapted the concept of replenishing inventory only when needed, creating the famous 'just-in-time' methodology.
TPS introduced revolutionary concepts including eliminating the seven wastes (muda): transportation, inventory, motion, waiting, overproduction, over-processing, and defects. The system emphasized continuous improvement (Kaizen), respect for people, and creating flow in production processes.
The term 'Lean' was coined in 1988 by John Krafcik in his article 'Triumph of the Lean Production System.' The concept gained widespread attention through the 1990 book 'The Machine That Changed the World' by James Womack, Daniel Jones, and Daniel Roos, which documented Toyota's superior manufacturing practices.
In 1996, Womack and Jones published 'Lean Thinking,' which expanded Lean principles beyond manufacturing to all business processes. This work identified five core principles: specify value, identify the value stream, create flow, establish pull, and pursue perfection.
During the 2000s, Lean merged with Six Sigma methodologies, creating Lean Six Sigma. This combination paired Lean's waste reduction focus with Six Sigma's statistical quality control approach. Today, Lean principles are applied across healthcare, software development, government, and service industries, demonstrating the methodology's universal applicability for operational excellence.
History of Lean: A Complete Guide for Six Sigma Green Belt
Why is the History of Lean Important?
Understanding the history of Lean is essential for Six Sigma Green Belt candidates because it provides context for why Lean principles work and how they evolved. Knowing the origins helps practitioners appreciate the philosophy behind waste elimination and continuous improvement. Exam questions frequently test this knowledge to ensure candidates understand the foundational concepts that shaped modern quality management.
What is the History of Lean?
Lean manufacturing has roots stretching back over a century, with several key milestones:
Early Foundations (Early 1900s) - Frederick Taylor introduced Scientific Management, focusing on work standardization and efficiency - Henry Ford revolutionized manufacturing with the assembly line and flow production at Ford Motor Company - Ford's system emphasized continuous flow but lacked flexibility for product variety
Toyota Production System (1940s-1970s) - Taiichi Ohno and Shigeo Shingo developed the Toyota Production System (TPS) in Japan - TPS incorporated concepts like Just-In-Time (JIT), Jidoka (automation with a human touch), and Kanban - Eiji Toyoda played a crucial role in implementing these systems at Toyota - The system was developed partly due to resource constraints in post-World War II Japan
Western Adoption (1980s-Present) - The term Lean was coined by John Krafcik in 1988 - James Womack, Daniel Jones, and Daniel Roos popularized Lean through their book The Machine That Changed the World (1990) - Womack and Jones further developed Lean thinking in Lean Thinking (1996)
How Lean History Connects to Modern Practice
The evolution from Ford's mass production to Toyota's flexible system demonstrates the shift from push to pull systems. Key principles that emerged include:
- Elimination of the Seven Wastes (Muda) - Respect for people - Continuous improvement (Kaizen) - Value stream focus - Pull-based production
Exam Tips: Answering Questions on History of Lean
Key Names to Remember: - Taiichi Ohno - Father of TPS - Shigeo Shingo - SMED and Poka-Yoke development - Henry Ford - Assembly line and flow production - James Womack - Coined broader Lean methodology for Western audiences
Common Question Types:
1. Attribution Questions: Know which person is credited with which concept. Ohno is typically associated with TPS and JIT, while Shingo is linked to setup reduction.
2. Timeline Questions: Remember that TPS developed in the 1940s-1970s, while Western Lean adoption occurred in the 1980s-1990s.
3. Terminology Origin: The word Lean came from Krafcik, not Toyota. Toyota called their system TPS.
Study Strategies:
- Create flashcards matching people to their contributions - Understand the logical progression from Ford to Toyota to Western Lean - Remember that Japanese post-war resource scarcity drove innovation at Toyota - Focus on the distinction between TPS (Toyota's system) and Lean (Western interpretation)
Watch Out For:
- Questions that mix up Ohno and Shingo's contributions - Trick questions about who coined the term Lean (not Toyota) - Questions about the sequence of historical developments - Distinguishing between Ford's flow production and Toyota's flexible flow