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TOYOTA PRODUCTION SYSTEM

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THE TOYOTA WAY TOYOTA PRODUCTION SYSTEM MAIN PILLARS OF TPS JUST IN TIME TAKT TIME(HEARTBEAT OF PRODUCTION) FLOW PRODUCTION PUSH VS PULL SYSTEM KANBAN CARD HEIJUNKA – LEVELLING THE FLOW JIDOKA GENCHI GENBUTSU – GOING TO THE SOURCE ANDON BOARD/WHEEL MISTAKE-PROOFING AND LABELLING KAIZAN A CULTURE OF CONTINUOUS IMPROVEMENT – ‘5S’

Contents

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The Toyota Way

Challenge Kaizen

Genchi Genbutsu Respect

Team Work

5 Core Values

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Toyota Production System

Provides Best Quality, Low Cost and Less lead time through the elimination of waste

Empower team members to optimize quality

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Toyota Production System

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1 JUST-IN-TIME

Main pillars of tps

2 JIDOKA

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Takt is the rate of customer demand – essentially, what the market is requiring be produced.

Takt time (Heartbeat of production)

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Producing and moving one item at a time (or a small and consistent batch of items) through a series of processing steps as continuously as possible, with each step making just what is requested by the next step.

Flow production

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Push system : material is pushed into downstream workstations regardless of whether resources are available.

Pull system: material is pulled to a workstation just as it is needed.

Push vs pull system

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• A smooth, continuous and optimized workflow, with carefully planned and measured work-cycle times and on-demand movement of goods, reduces the cost of wasted time, materials and capacity.

Kanban card

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It is the opposite of mass production series, in which high volumes of a single product are produced, often significantly unrelated to demand

With heijunka a process is designed to switch products easily, producing what is needed when it is needed, and relying on production.

Heijunka – leveling the flow

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Jidoka translates as “automation” and can be described as “automation with a human touch”.

If a defect or error is identified it is addressed immediately – even if this means temporarily stopping production.

Jidoka

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It means going to the actual place to solve the problem.

which means ‘going to the source’ of the problem and assessing it for yourself rather than relying on information supplied by others, in order to gain a complete and accurate understanding.

Genchi genbutsu – going to the source

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Andon board/wheel

• The Andon board is a simple but highly-visible electronic sign displaying the status of production lines.

• It notifies management immediately if a worker has identified a fault, precisely identifying its location.

• The production line will not be restarted until the reason for the fault has been resolved.

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Devices that make it difficult or impossible for a worker to make typical errors at his or her workstation are a common sight on Toyota production lines.

Mistake- proofing and labeling

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Kaizen means that all team members throughout the organization are continuously looking for ways to improve operations, and people at all levels in the company support this process of improvement.

Kaizan

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A CULTURE OF CONTINUOUS IMPROVEMENT – ‘5S’

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Thank you