TOYOTA

PRODUCTION
SYSTEM
Presented By-
MOHD.ARISH
 INTRODUCTION
The Toyota Production System (TPS) is an integrated socio-
technical system, developed by Toyota, that comprises its
management philosophy and practices.

The TPS organizes manufacturing and logistics for the

automobile manufacturer, including interaction with suppliers
and customers.

The system is a major precursor of the more generic "Lean

manufacturing.
CONTD…………
1897:- Sakichi Toyoda diversified his business.

1926:- He formed Toyoda Automatic Loom Works (TALW) to

manufacturing Loom workers

1933:- Established an Automobile department within TALW.

1935:- First Passenger car prototype was developed.

1936:- Sakichi sold the patent rights of his Automatic loom to a UK

based Company.

1947:- The passenger cars production began.

1950-1955:- Foundation of Kanban System.

 1957:- Eijji Renamed Toyota as “The Toyota Company”

 1968:- Toyota’s first export to the USA.

 1970s:- Major boost in the Japan due to oil crises.

 1980s:- Toyota brought TPS in the USA with a Joint Venture to The GM.

 1983:- Company’s name changed to Toyota motor Corporation.

 1988:- Toyota Opened its New plant in Georgetown.

 1999-2000:- Toyota listed on NYSE & LSE and become one of the top
manufactures of cars in the world.
 TOYATA PRODUCTION SYSTEM
Tahchi Ohno’s ( Assembly manager)

 Simplify the concept and develop them into formal system.

 Experimented various ways of setting of the equipment.

 Trained the engineer’s about how to use and implement the system.

 Efficient use of available resources by reducing wastes and lowering costs.

 FEATURES OF TPS

JIT
TECHNICAL
RELATED
KANBAN
TPS
WORKERS
PEOPLE
RELATED
SUPPLIERS
 JUST IN TIME (JIT)
 It is foundation of TPS.

 Right use of time and amount

 JIT become important because of scarce flat, industrial, land.

 Advantage of making its own component

 KANBAN

KANBAN

WITHDRAWL
PRODUCTION
CONVEYANCE
 Kanban is used to facilitate the movement of inventory between
different process on the production line.

 Withdrawal Kanban is carried when going from one process to the

preceding process.

 Production Kanban is used to order production of the portion

withdrawn by the subsequent process.
 KAIZAN
It is small incremental changes made for improving productivity and
minimizing waste.

 Improvement of process flow to reduce wastage.

 The changes are generally small and incremental.

 Observation is best way to spot problems.

 Understand problem.
 BENEFITS OF KAIZAN
 Reduces waste

 Improvement

 Result in higher employee

 HUMAN ELEMENT

The main consideration in TPS:-

 Elimination of wasteful movements by workers.

 Consideration of workers safety.

 Self display of workers capabilities by entrusting them with

responsibility and authority.

 TPS Emphasized on flexibility and teamwork.

 Strong Making best use
of its resources
relationship got greater
with suppliers productivity

Achieve a
high degree
Benefit
of flexibility s

Less time for

implementati
on
 PROMOTION

 Toyota set up the TSCC ,headquartered in Kentucky

 Toyota did not charge any fee for its services, and only the
consultants expenses had to be reimbursed by the client.
 SYSTEM OF THE FUTURE
 Standard global production system of the future.

 Successful companies from US & Europe implementing TPS.

 General Mills, a major US food company.

 Gorton’s fish processing unit- in reducing inventory.
 Hickory Chair kept prices steady for 3 years by
adopting TPS & FUJITSU company recovering from
losses by implementing TPS in streamline operations.