25/8/2016 SupplyChainManagement:FordProductionSystem:AnSuccessfulAdoptionofLeanManufacturing

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FordProductionSystem:AnSuccessfulAdoptionofLean
Manufacturing
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FashionForward
LeanmanufacturinghistoryTheFordSystem ZarasSupply
As we known, lean manufacturing, which also refers as Toyota Production System (TPS), is created at Toyota. ChainStrategies
Onedayitsin
However,therootsofTPScanbefoundinHenryFordssystemoflineassemblyandmanufacturingprocess.In andthenextday
theFordsystemthey manufactured automobiles in large quantities of standarddesigns,whichmadethesystem itsoutapopularphrase
highlyefficient,deliveringaproductwithlowcost. thatoftenresoundswhenthe
apparelindustrycomesto
mind.Thefashioni...
Main idea of the Ford system is the standardized product, which lead to the standard processes. Training of
workersbecameeasily,andanyonecanworkintheFordplantwithinnotime.Allworkershavetheirownduty Amazon's
SupplyNetworks
and only need to perform a specific small part of the full job like tightening a screw or oiling a part. Moving Strategy
assemblylinemadeitpossibletomanufactureinthewayFordexpects,likeworkershadtoadapttothespeedof Amazon.com,
the conveyer. This will remove the personal element from the production line. The full system was in a Inc.isan
Americanmultinational
harmonizationwiththerhythmoftheassemblyline. electronicscommerce
companywithheadquarters
After learning from Ford system, Toyota identified the problem that standard products could not meet the all inSettleWashington,United
St...
customer demands, and then generated the unique Toyota Production System (TPS). Instead of the Ford push
system, Toyota created a unique pull system, which then became the backbone of lean manufacturing, to avoid Ikea'sLowPriceStrategy
overproductionandmeetthediversifiedcustomerdemands. Ikeas
LowPriceStrategy"Todesign
Leans fundamental principles developed by Toyota are universally accepted but commonly adapted to each
adeskwhichmaycost$1,000
organization or industry. One example of these transformations is Ford Motor Company, indicating the Ford iseasyfora...
ProductionSystem.
Dellmodifiesits
supplychain
FordProductionSystem strategy
Dellmodifiesits
In January 1995, Ford initiated Ford 2000 program, which was aim to develop and implement a new supplychain
manufacturingsystemcalledtheFordProductionSystem(FPS).AccordingtoFord'swebsite,"ThevisionofFPS strategyThisblogpostisin
isalean,flexibleanddisciplinedcommonproductionsystem,definedbyasetofprinciplesandprocesses,that relationtothefirstweeks
readingassignmentandfrom
employsgroupsofcapable and empowered people, learning and workingsafelytogether,intheproductionand anarticletha...
deliveryofproductsthatconsistentlyexceedcustomers'expectationsinquality,costandtime."Byimplementing
Flipkart's
FPS,Fordattemptedtotransformitselffrommassproductionsystemtoleanmanufacturingsystem.
inventory
management
Byutilizingpolicydeployment,visualmanagement,processconfirmation,andtimeanddatamanagement,FPS Flipkartisan
willdeliveramorealignedandcapableorganization,whichwillbecontinuallyimprovingandultimatelybuilding electronic
commercecompanyand
abettermanufacturingenvironmentsinthefuture.TheimagebelowistherevisedManufacturingUmbrella. amongIndiaslargestonline
retailerswithreportedsalesof
$12.5million.Fl...

Apple'sSupply
Chain
Management
Applehas
createdanew
marketandchangedthe
structuresofmusicand
mobileindustries.Apple's
iPadcontributedtoincrease
inpurcha...

CROSSDOCKING
WALMATSINVENTORY
STRATEGY
Crossdockingwhichis
definedasthepracticein
logisticsmanagementof
unloadingmaterialsfroman
incomingtrailertri...

KanbanJustin
TimeProduction
Whilereading
articleson
Toyotas
ProductionSystemIcame
acrossthetermKanban.

http://cmuscm.blogspot.com/2013/02/adoptionofleanmanufacturingford.html 1/6
25/8/2016 SupplyChainManagement:FordProductionSystem:AnSuccessfulAdoptionofLeanManufacturing
Kanbanisderivedfromthe
combinationoftwoJapanes...

FordProduction
System:An
Successful
AdoptionofLean
Manufacturing
Leanmanufacturinghistory
TheFordSystemAswe
known,leanmanufacturing,
whichalsorefersasToyota
ProductionSystem(TPS),i...

H&M'ssecretto
cheap,
afforadableand
fashionable
clothing:
Outsourcing
H&Mopeneditsfirststorein
Vasteras,Swedenintheyear
1947.TodayH&Mhas
expandedtoover3300stores
in54countries...

TotalPageviews

1,020,330
The FPS Continuous Improvement Model is the foundation for all manufacturing operations. It is a ten step
processthatisaimedatcontinuallyimprovesprocessesthroughstandardizationandandonrecognition.Themodel AboutMe
looksforcreatingstabilitytoinputs,normalizeprocesses,andseekingchange(ifnecessary)foroutputs.Theten
FPSContinuousImprovementModelProcessesare:
ContinuousImprovementBoard Viewmy
complete
Start+upConfirmation
profile
ResultsProcess
SupportProcess
TimeandDataManagement
BasicAdministration
Kaizen
StandardizedWork
StarPoints

LeanManufacturinginPractice
Lean manufacturing aimed at bringing together people, material and mechanical resources at the right time to
accomplishthejob,whilereducingcostandbringcontinuousimprovement.Itstrivedtoeliminatesevenkindsof
waste including waste from over production, waste of waiting time, transportation waste, processing waste,
inventorywaste,wasteofmotionandwastefromproductdefects.

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25/8/2016 SupplyChainManagement:FordProductionSystem:AnSuccessfulAdoptionofLeanManufacturing

ProductionSystemsofTheFuture
By2003,alltheplantsofFordhadadoptedFPSintheiroperations.Itwasestimatedthataftertheimplementation
ofFPS,Fordhadachievedsavingstothetuneof$500millionperyear.Thepersonnelattheplantsalsoreceived
webbasedtrainingwhilebestpracticeswereidentifiedandsharedbetweentheplants.Bymid2003,Fordwasin
the process of standardizing manufacturing operations across all its plants globally. The company planned to
implementstandardoperatingproceduresanduniformplantlayouts.

FPS is our blueprint for today and for the future, said John Fleming, executive vice president, Global
ManufacturingandLaborAffairs.Itsaboutbringingprocessestogether.Itsaboutlearningfromeachother.And
itsabouthavingoperatingsystemsdevelopedfrombestpracticesfromaroundtheworldwhicharetrulythebest
waythatweknowhowtobuildvehicles.

Question:
ItturnsoutthatFPSsuccessfullyhelpdFordtosavemoney,however,sincethereisnostatisticalorsystemanalysis
inFPS,canFPSkeepsservingaccuratelyinremovingwasteandprovidingcontinuousimprovementinthefuture?
ThesustainabilityofimprovmentofFord,byadoptingleanmanufacturing,shouldtakeintoconsideration.

[1]http://www.ford.com.au/?
WT.srch=1&WT.mc_id=ac01_FoA&gclid=CNX2sp3YwrUCFYcipQodSiYAdA&pkw=ford+website&pmt=b
[2]Miller,Geoff,JanicePawloski,andCharlesRobertStandridge."Acasestudyoflean,sustainable
manufacturing."JournalofIndustrialEngineeringandManagement3.1(2010):1132.
[3]http://www.at.ford.com/SiteCollectionImages/2011_U.S._Plant_Pages/Rawsonville/FordProductionSystem.pdf
[4]
http://www.at.ford.com/news/cn/Pages/Ford%20Production%20System%20drives%20success%20at%20Ford%20M
otor%20Company.aspx
[5]Zarbo,RichardJ.,andRitaDAngelo."TheHenryFordProductionSystemEffectiveReductionofProcess
DefectsandWasteinSurgicalPathology."Americanjournalofclinicalpathology128.6(2007):10151022.

PostedbyZikunXuat8:10AM Recommend this on Google

4comments:

RajFlowrack May13,2013at3:43AM
LeanManufacturingsystemplansoutanactionforbetterqualityoutputonIndustrialProductioninagiven
time.
Reply

Manjotkaur February12,2015at3:23AM
Youhavewrittenwonderfularticle.Greetingsandthankyou..
mbaexecutivechandigarh
Reply

JohnRobert February22,2016at11:11PM
Nicearticledearauthor,Ireallyagreewithyouandwouldliketoappreciateyoumoreaboutbutonething
more which I felt that missing was only Kaizen training, that is now known a major part of lean and 5s
supplies, I'd like to suggest you get more knowledge about this one and wish if you share with all of us
thanks!
Reply

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25/8/2016 SupplyChainManagement:FordProductionSystem:AnSuccessfulAdoptionofLeanManufacturing

SumuduMalinda March29,2016at9:56AM
verygoodarticlethanksbro
Reply

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