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toyota production system

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Vinodkumar Degalmadi

The document discusses the key principles of the Toyota Production System (TPS), including just-in-time production, continuous flow, pull systems using kanban cards, load levelling across processes, autonomation with human touch through jidoka, problem-solving by going to the source with genchi genbutsu, use of andon boards to identify issues, mistake-proofing, and a culture of continuous improvement known as kaizen.

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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’ 2
3 Challenge Kaizen Genchi Genbutsu Respect Team Work 5 Core Values
4 Provides Best Quality, Low Cost and Less lead time through the elimination of waste Empower team members to optimize quality
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1 JUST-IN-TIME 6 2 JIDOKA
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? Takt is the rate of customer demand – essentially, what the market is requiring be produced. 8
? 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. 9
? 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. 10
? 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. 11
? 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. 12
? 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. 13
? 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. 14
15 ? 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.
? 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. 16
? 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. 17
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toyota production system

  • 1. 1
  • 2. ? 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’ 2
  • 4. 4 Provides Best Quality, Low Cost and Less lead time through the elimination of waste Empower team members to optimize quality
  • 5. 5
  • 7. 7
  • 8. ? Takt is the rate of customer demand – essentially, what the market is requiring be produced. 8
  • 9. ? 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. 9
  • 10. ? 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. 10
  • 11. ? 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. 11
  • 12. ? 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. 12
  • 13. ? 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. 13
  • 14. ? 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. 14
  • 15. 15 ? 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.
  • 16. ? 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. 16
  • 17. ? 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. 17
  • 18. 18
  • 19. 19

Editor's Notes

  1. This is followed by toyota employees at every level in their daily work and relations with others. This is how toyota is able to deliver sustainable customer satisfaction.