BASIC FRAME WORK OF TOYOTA PRODUCTION SYSTEM (TDS)

BASIC FRAME WORK OF

TOYOTA PRODUCTION
SYSTEM (TDS)

Presented by: ASHWATH SINGE

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 BASIC FRAME WORK OF TOYOTA PRODUCTION SYSTEM (TDS)

CONTENT
• Goals of TPS
• Toyota Ways
• How to make money ????
• Toyota Production System
• TPS-House
• Main pillar of TPS
• Just-In-Time( Takt time,Pull System,Flow production)
• Heijunka
• Waste (INVENTORY)
• Jidoka
• Andon Wheel
• Standardization
• Mistake proofing
• Visual management
• Kaizen
• 5’s
• The Environment – Toyota’s commitment
• Health and Safety
• What TPS Means for your Business

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 BASIC FRAME WORK OF TOYOTA PRODUCTION SYSTEM (TDS)

GOALS OF TPS
The goal of the Toyota Production System is to provide products at world
class quality levels to meet the expectations of customers, and to be a model
of corporate responsibility within industry and the surrounding community.

The Toyota Production System historically has had four basic aims that are
consistent

with these

values and objectives: The four goals are as follows:

1. Provide world class quality and service to the customer.

2. Develop each employee’s potential, based on mutual respect, trust and

cooperation.

3. Reduce cost through the elimination of waste and maximize profit

Develop flexible production standards based on market demand.

The TOYOTA WAY

The five core values of The Toyota Way are shared and practiced 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.

Continuous Respect For People

Improvement

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 BASIC FRAME WORK OF TOYOTA PRODUCTION SYSTEM (TDS)

Respect For People

Traditional pricing strategy: Cost + Profit = Selling price

Example: When the cost goes up, the product selling price is raised to reflect
the higher costs and maintain the desired level of profit.

Some even argues that the profit added should be large enough to cover
potential losses if the product does not sell well.

Toyota accepts neither this formula nor these

arguments!

Toyota's philosophy
Selling price – Cost = Profit

Customers decide the selling price.

Profit is what remains after subtracting the cost from it.

The main way to increase profit is to reduce cost.

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 BASIC FRAME WORK OF TOYOTA PRODUCTION SYSTEM (TDS)

Consequently, cost reduction through waste elimination should have the

highest

priority.

Toyota's paradox: Reducing cost (waste), will reduce lead time while
increasing quality and customer satisfaction.

How? We will discuss it soon.

Toyota Production System

Definition: The production system developed by Toyota Motor Corporation
to provide best quality, lowest cost, and shortest lead time through the
elimination of waste.

The Toyota Production System empowers team members to optimize

quality by constantly improving processes and eliminating unnecessary
waste in natural, human and corporate resources.

It entrusts employees with well-defined responsibilities in each production

step and encourages every team member to strive for overall
improvement.

Main Pillars Of TPS

• JUST-IN-TIME

• JIDOKA

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 BASIC FRAME WORK OF TOYOTA PRODUCTION SYSTEM (TDS)

• JUST-IN-TIME- smooth, continuous,

optimized workflows……………….
• JIT is a manufacturing philosophy involving an integrated set of
procedures/activities

designed to achieve a volume of production using minimal inventories

OR

• A philosophy that seeks to eliminate all types of waste, including

carrying excessive levels of inventory and long lead times.

• Takes its name from the idea of replenishing material buffers just
when they are needed and not before or after.

Best applied to a production system, such as automobile assembly, that

would be considered repetitive, such as a flow shop.

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 BASIC FRAME WORK OF TOYOTA PRODUCTION SYSTEM (TDS)

JIT Elements Are:

• Takt Time

• Flow Production

• Pull system

TAKT TIME(Heartbeat of production)

• Takt is the rate of customer demand – essentially, what the
market is requiring be produced.
• It is the basis on which we can create flow within our work-cells and
throughout our whole value chain from raw materials to customer
delivery.

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 BASIC FRAME WORK OF TOYOTA PRODUCTION SYSTEM (TDS)

• Takt time is the available working time for production divided by the
actual average daily demand for our product(s) expressed in minutes.
this gives us the customer demand rate for use throughout our
organization and the supply chain.
• The Takt time also forms the basis for enabling the design and
balancing of our work-cells and production lines in an efficient
manner.

FLOW PRODUCTION
• 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.

It is also called the one-piece flow, single-piece flow, and make one, move
one.

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PUSH vs PULL SYSTEM

• 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

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• Traditional Manufacturing Way:

• One directional flow system:

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• Pull (JIT) System

The production of items only as demanded for use or to replace those
taken for use.

HEIJUNKA – LEVELLING THE FLOW

• The term heijunka describes the foundation of the TPS approach.

• It is the opposite of mass production series in which high volume of

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.

• Any variations in volumes are accommodated by establishing a

level-average demand rate.

• It will reduce the ripple effect of the production.

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Small versus Large Lots

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• ELIMINATION OF WASTE
Waste – defined as anything that does not add value.

KANBAN CARD
• 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.

• Team members can concentrate on their tasks without interruption,

which leads to better

quality, timely delivery, and peace-of-mind for Toyota’s customers.

• In TPS it means having just the right components to build the product.

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• JIDOKA……. building in quality

• 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.

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.

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• Workers take responsibility for production quality, with the power to

stop the production line as required.

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

STANDARDISATION
• key element for quality assurance is a focus on standardization.

• Developing and relying on standardized work tasks not only ensures

consistently high levels of quality, but also maintains production pace
and provides a benchmark for implementing continuous
improvement.

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• VISUAL MANAGEMENT
• In shop floor the things are visually display so that every one can
excess them.

• Provide safety features for employs like by visually representing the

Heights, how to carry load, how to move pallet truck etc.

• Help's visitor to excess plan without the help of others.

• It also applies for tools,materials,documents etc.

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The Environment – Toyota’s commitment

• Toyota has a policy in place to reduce CO2 emissions, use resources
more efficiently, and reduce environmental risk factors.

• Its policy is to analyze the effects of every stage in its products’

lives: development,

manufacturing, operation, and recycling.

• TPS philosophy also includes the 3Rs – reduce, reuse, recycle

manufacturing sites have all achieved ISO 14001 certification.

TPS IS CONCERNED WITH Health and Safety

• Toyota maintains health and safety for its team members so they can
concentrate on their jobs delivering the best quality products and be
more efficient.

• Manufacturing sites have achieved OHSAS

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18001 certification –the international

standard for occupational health and safety management.

OHSAS 18001 is a British Standard for occupational health and safety

management systems

What TPS Means for your Business

• Toyota’s customers know what to expect when they buy from Toyota
– a business

partner with the strength and flexibility to meet the needs of a changing
market

• Quality inherent in Toyota’s products, thanks to the company’s

constant striving for improvement, has direct benefits for their
customers…

• Costs are kept to a minimum thanks to a good return on investment

based on the productivity and reliability of Toyota's products…

• Delivery is on time, and to the expected standard, allowing Toyota's

customers to plan and maintain their operations successfully…

• Environmental concerns are shared by Toyota and its customers, from

manufacturing through to recycling at end-of-life. Choosing Toyota
products is a good choice for the environment…

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REFERENCE
1.Basic image of lean production concept from lean and simplified text book
page no 24

2. basic framework of TPS concept from just in time manufacturing p.no 24

3. case study mass production v/s batch production from sciencedirect.com

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