TOYOTA PRODUCTION SYSTEM

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VisionContribute to Indian industry and economy

through technology transfer, human resource development and vehicles that meet global standards at competitive price.

Contribute to the well-being and stability of team members.

Contribute to the overall growth for our business associates and the automobile industry.

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MissionOur mission is to design, manufacture and

market automobiles in India and overseas while maintaining the high quality that meets global Toyota quality standards, to offer superior value and excellent after-sales service. We are dedicated to providing the highest possible level of value to customers, team members, communities and investors in India.

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7 Principles of Toyota Production SystemReduced setup timeSmall-lot productionEmployee Involvement and EmpowermentQuality at the sourceEquipment maintenancePull ProductionSupplier involvement

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TOYOTA PRODUCTION SYSTEM

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Production System

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JUST-IN-TIME

Produced according to what needed, when needed and how much needed.

Strategy to improve return on investment by reducing inventory and associated cost.

The process is driven by Kanban concept.

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KANBAN CONCEPTMeaning- Sign, Index Card It is the most important Japanese concept opted by

Toyota.Kanban systems combined with unique scheduling

tools, dramatically reduces inventory levels.Enhances supplier/customer relationships and

improves the accuracy of manufacturing schedules.A signal is sent to produce and deliver a new

shipment when material is consumed. These signals are tracked through the refill cycle

and bring extraordinary visibility to suppliers and buyers.

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Just-in-time --- BenefitsSet up times are significantly reduced in the

warehouse.The flows of goods from warehouse to shelves

are improved. Employees who possess multiple skills are

utilized more efficiently. Better consistency of scheduling and

consistency of employee work hours. Increased emphasis on supplier relationships

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JIDOKAJidoka (meaning ‘autonomation’)-a term used

in Lean manufacturing meaning "automation with a human touch."

It is a quality control process used in the Toyota Production System which applies the following four principles:

Detect the abnormality. Stop. Fix or correct the immediate condition. Investigate the root cause and install a

countermeasure.

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Jidoka

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Lean ManufacturingMost important concept of Toyota Production

SystemA management philosophy focusing on

reduction of the seven wastes to improve overall customer value.

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Key Principles Pull processing products are pulled from the

consumer end (demand), not pushed from the production end (Supply)

Perfect first-time quality quest for zero defects, revealing & solving problems at the source

Waste minimization eliminating all activities that do not add value & safety nets, maximize use of scarce resources (capital, people and land)

Continuous improvement reducing costs, improving quality, increasing productivity and information sharing

Flexibility producing different mixes or greater diversity of products quickly, without sacrificing efficiency at lower volumes of production

Building and maintaining a long term relationship with suppliers through collaborative risk sharing, cost sharing and information sharing arrangements.

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seven wastes to improve overall customer value [ MUDA ]

Transportation Inventory Motion Waiting time Over-production Processing Itself Defective Product (Scrap in manufactured

products or any type of business.)

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Other Toyota Production Concepts

Heijunka (Production Smoothing)Kaizen (Continuous Improvement)Poke-Yoke (to avoid inadvertent errors)Andon (Signboard)Mura,Muri

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Heijunka (Production Smoothing)

Heijunka is Japanese term that refers to a system of production smoothing designed to achieve a more even and consistent flow of work.

Heijunka as a concept is closely related to lean production and just in time manufacturing.

A related visual scheduling board known as a heijunka box is often used in achieving heijunka style efficiencies.

The use of heijunka as well as broader lean production techniques helped Toyota massively reduce vehicle production times as well as inventory levels during the 1980s.

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KaizenMeaning- Continuous ImprovementKaizen refers to a workplace 'quality' strategy

and related to various quality-control systems. It aims to eliminate waste (defined as "activities

that add cost but do not add value"). Kaizen is a daily activity whose purpose goes

beyond improvement. It is also a process that, when done correctly, humanizes the workplace, eliminates overly hard work (both mental and physical.

It teaches people how to perform experiments using the scientific method and how to learn to spot and eliminate waste in business processes.

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Poke-YokePoka-yoke (means "fail-safing" or "mistake-

proofing" — avoiding (yokeru) inadvertent errors (poka))

is a behavior-shaping constraint, or a method of preventing errors by putting limits on how an operation can be performed in order to force the correct completion of the operation.

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Andon (Signboard) Andon is a manufacturing term referring to a signboard

incorporating signal lights, audio alarms, and text or other displays installed at a workstation to notify management and other workers of a quality or process problem.

The alert can be activated manually by a worker, or may be activated automatically by the production equipment itself. Typically, it will incorporate both a visual indicator and an audible alarm.

An Andon system is one of the principle elements of the Jidoka quality-control method pioneered by Toyota and now part of the Lean methodology.

It gives the worker the ability to stop production when a defect is found, and immediately call for assistance.

Work is stopped until a solution has been found out. The alerts may be logged to a database so that they can be studied as part of a continuous-improvement program.

The system will typically indicate where the alert was generated, and may also provide a description of the trouble.

Modern Andon systems can include text, graphics, or audio elements.

Audio alerts may be done with coded tones, music with different tunes corresponding to the various alerts, or pre-recorded verbal messages.

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Mura , Muri Mura Mura is a Japanese term for unevenness. It is also a key concept in the Toyota Production System

and is one of the three types of waste (Muda, Mura, Muri) it identifies. Waste reduction is an effective way to increase profitability.

Muri Muri is a Japanese term for overburden or

unreasonableness. It is also a key concept in the Toyota Production System

and is one of the three types of waste (Muda, Mura, Muri) it identifies. Waste reduction is an effective way to increase profitability.

Muri can be avoided through standardised work.

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Conclusion

A Production System that is steeped in the philosophy of the complete elimination of all

wastes and that penetrates all aspects of production with this philosophy in pursuit of

the most efficient production method.

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