Tout d’abord, on ne peut dissocier la naissance et l’adoption proressive du Lean management et l’histoire industrielle. Basiquement, l’industrie est passée d’un mode de production manuelle que l’on pourrait qualifier d’individualisée (19ème siècle) à une mécanisation faisant sortir de chaîne des produits standardisés (20ème siècle).
Après la seconde guerre mondiale, la croissance aidant, les fabricants ont évidemment gardé les machines pour produire mais ont de plus en plus eu pour objectif de livrer des produits finis personnalisés. C’est là qu’il a fallu adapter les méthodes pour rester compétitif en qualité, en délai de fabrication et de livraison, en prix. C’est à cette époque, dans les années 1950, qu’un ingénieur de chez Toyota, Taiichi Ohno, invente le Toyota production system (TPS). Légende ou vérité américaine (?), on raconte qu’il eut cette idée après un voyage aux Etats-Unis et une observation de la bien connue course des 500 miles d’Indianapolis et en particulier l’organisation de ses ravitaillements et arrêtes aux stands. On raconte aussi qu’il visita une usine Ford et fut impressionné par le flux et le rythme des chaînes d’assemblage. Ford, aujourd’hui loin derrière Toyota, pourrait s’en mordre les doigts…
Mais qu’est-ce que le TPS ? C’est un système où les employés sont encouragés à maîtriser les pertes, à travailler ensemble en équipe, et à s’engager dans un processus d’amélioration continue. Les ouvriers sur la chaîne n’ont pas besoin d’être dirigés. Ils savent quoi faire. Ils doivent se concentrer sur comment augmenter leur propre productivité.
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