Applying Lean-TRIZ hybrid approach into Toyota kata for organizational level improvement

Thiago Bastos Fernandes, Rodrigo Bastos Fernandes, Fernando Antônio Forcellini

Abstract


The pursuit for competitive advantages demand manufacturers to increase flexibility, productivity and profitability, while reducing operational cost an idle time. The Japanese manufacturer Toyota was capable to develop a unique method to treat those issues, originating the Toyota Production System. This concept was studied, westernized and widely spread as Lean Manufacturing, predominantly by applying best practices – e.g. Kanban, A3 and Value Stream Mapping – from the Japanese facility. Through a variety of reports about unsustainability the mindset behind the improvement was researched, out coming the Toyota Kata approach. This method identified the patterns of relationship among the command chain and the way of identify and solve problems seeking improvement and knowledge, this may be described and a study-action approach. This project presents a Lean-TRIZ proposal for empower organizational level with a systematic support for Challenge creation, meaning to define long term systems operational characteristics. A method based on the state of the art Lean-TRIZ was developed and verified by simulations, hence proposed challenges were evaluated by experts according to quantity, utility and novelty of ideas. Finally, the data was statistically analyzed proving the integrated model capabilities.


Keywords


Lean manufacturing; Continuum improvement; TRIZ; Improvement Kata

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