1 0. Introduzione ____________________________________________________________ 4 0.1 Obiettivo della tesi_________________________________________________________ 5 0.2 Strutturazione del lavoro ___________________________________________________ 5 0.3 Ricerca bibliografica __________________________________________________________ 6 0.4 Ringraziamenti ______________________________________________________________ 7 1. Cos’è la Lean Production ___________________________________________________ 8
1.1 Origini ed evoluzione ______________________________________________________ 8 1.2 I principi della Lean production ____________________________________________ 12 1.3 Toyota Production System _________________________________________________ 19
1.3.1 La Time Line _________________________________________________________________ 20 1.3.2 Il sistema produttivo pulsante ____________________________________________________ 21 1.3.3 La standardizzazione ___________________________________________________________ 22 1.3.4 Operatore ed il ruolo del Team ___________________________________________________ 23 1.3.5 Il metodo del Production Preparation Process ________________________________________ 24 1.3.6 La direzione per politiche _______________________________________________________ 26 1.3.7 Il metodo Jidoka ______________________________________________________________ 27 1.3.8 Il metodo Just in Time (JIT) _____________________________________________________ 29 1.3.9 Il sistema Pull ________________________________________________________________ 30 1.3.10 Il sistema One-Piece-Flow ____________________________________________________ 30 1.3.11 Il Takt time ________________________________________________________________ 32 1.3.12 Heijunka __________________________________________________________________ 33 1.3.13 Il “basamento” del TPS_______________________________________________________ 35
1.4 Prospettive di trasferimento del Toyota Production System _____________________ 42 1.5 Il Lean Thinking e l’Azienda Snella _________________________________________ 44 2 Misurare l’efficacia e l’efficienza di un sistema produttivo______________________ 48
2.1 Up Time ________________________________________________________________ 48 2.2 First Part Yield __________________________________________________________ 48 2.3 Efficienza _______________________________________________________________ 49 3 Il Value Stream Management _____________________________________________ 50
3.1 Generalità ______________________________________________________________ 50 3.2 Il flusso del valore ________________________________________________________ 50 3.3 Le fasi di gestione del flusso del valore _______________________________________ 51 3.4 L’impegno Lean _________________________________________________________ 52 3.5 La scelta del flusso del valore_______________________________________________ 54 3.6 Gli strumenti Lean _______________________________________________________ 55 3.7 Value Stream Mapping____________________________________________________ 59
3.7.1 Descrizione delle mappe del flusso ________________________________________________ 60
3.8 La mappatura dello stato attuale____________________________________________ 66 3.9 La mappatura dello stato futuro ____________________________________________ 71 4. L’azienda _______________________________________________________________ 76
