Toyota Production System

by : Iskandar Syahril Ibrahim Sukri (P50078)

Toyota Motor Co. Ltd was established by Kiichiro Toyoda in 1937 as a spin-off from Toyoda Automatic Loom Works

Toyota launched its first passenger

car in 1947

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FOUNDER OF TPS'Toyota Production System’ was established in 1970 by Taiichi Ohno. Based on the principles of JIDOKA, JUST-IN-TIME and KAIZEN, REDUCTION OF INVENTORIES and DEFECTS in the plants of Toyota and its suppliers

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•Design out overburden(muri), inconsistency(mura) & eliminate waste(muda)

• Process of production is as flexible as possible

• Follows 5 s approach- sieri(sort), seiton(set in order), seiso(shine), seiketsu (standardize), shitsuke(sustain)

• Participation of all employees in the work process

• Elimination of imperfection or problem so as to reduce inventory

• Systems thinking- tools & techniques are highly interdependent

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Another thing to consider: Most improvement methodologies concentrate on reducing labor hours. Unfortunately, touch labor is generally a very small percentage of the total cost of most modern products.

There is, however, another way to look at this: If you push the process down through all your suppliers, the only factors that are not people’s “labor” are the ore in the ground, oxygen in the air, water in the streams, and sources of energy. So the total people costs usually are a large percentage of the final cost. And even though touch labor in assembly is not a great cost driver, it is often a significant time driver, which (as a component of OODA loops) may have a greater impact on competitiveness than just cost.

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-Autonomous automation for 100% zero defect production

JIDOKA = AUTONOMATION = AUTOMATION WITH HUMAN INTELLIGENCE

4 Principles of Autonomation

1. Detect the abnormality.

2. Stop.

3. Fix or correct the immediate condition.

4. Investigate the root cause and install a countermeasure.

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JIT- philosophy of continuous improvement that puts emphasis on prevention rather than correction, and demands a company wide focus on quality.

JIT- operational management approach to world class manufacturing.

JIT- production is based on demand

Just in Time is delivery of the needed amount at the right time:

•buffer free

•store free

•kanban

•involvement of the supplier in the kanban

• system

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Advantages of going TPS:

Companies that pursue and emulate TPS best practices have seen much success as a result of this highly effective manufacturing philosophy. Some of the benefits include:

•Identify and enhance customer perceived value

•Decrease waste and cost in the manufacturing process

•Improve product quality and on-time delivery

•Develop a competitive world class manufacturing operation

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