Evolution of Toyota

Production system with Time

Line
 Beginning Of
Journey
1896 - Developed Toyoda Power Loom with a weft-breakage
automatic stopping device
1924 – Developed World's first automatic loom with a non-stop
shuttle-change motion, the Type-G Toyoda Automatic Loom

Sakichi Toyoda
(1867-1930)

1927 – Introduction of flow production method using a

chain conveyor into the assembly line of a textile plant
1938 - Introduced this method into the body production line
at Toyota Motor Co., Ltd.'s Koromo Plant (present day Honsha
Kiichiro Toyoda Plant)
(1894-1952)
 Beginning Of Journey
(Contd…)
1938 ~ 1954 Thorough implementation of jidoka and the Just-
in- Time method (using flow based Layout, Kanban and
Goguchi production control system), workers' productivity
increased by adding value and realized the Toyota Production
System.
Eiji Toyoda
(1913-2013)
Taiichi Ohno helped establish the Toyota Production System
(With strong backing from Eiji Toyoda), and built the foundation
for the Toyota spirit of "making things" by, for example,
creating the basic framework for the Just-in-Time method. He

Taiichi Ohno was credited for real implementation on floor

(1912-1990)
Pillars Of Toyota Production System
2 Pillars of Toyota Production system along with its elements are
depicted below

Pull System of
Production
When a problem is
Transporting only detected, production
lines stop and an
when is needed alert is displayed
Producing products

Jidoka
within a flow
Producing products
in smaller lots Separation of
operator’s work and
Production Leveling machine’s work
based on takt time
 Pull System of Production
JIT

Pull system Elimination Adoption of Adoption of Adoption of

of of Red/Blue tag kanban e-kanban for
production intermediat system for card for long distance
adopted e accepting parts suppliers
warehouse; deliveries supplied
from from

1993
1961

1965
1948

outside suppliers
9 suppliers
1

5
4

1999
1955

1963
Fill up 1 Adoption Company Adoption 1 Adoption
system of 9 of system to wide 9
of automatic of e-kanban
production5 take adoption of kanban 7 system
adopted in4 deliveries of kanban reading 7
machining parts in set system machines
plants quantities
 Transporting only when is needed
JIT

Adoption of Adoption of Adoption of Shortening Adoption of

relay system relay system lead time by Joint
conveyance for delivering for supplier reassessing Transport of
callout materials trucks logistics completed
system in between Vehicles
machining plants

1998
1973

1983
1953

plants
9
1

5
9 1970

1977
Adoption 1 Expansion Adoption Adoption 1
of set 9 of the of circling of combined9
quantity 5 conveyance transport marine and9
delivery 5 callout of land 5
system to mixed transport for
all plants loads remote
locations
 Producing products within a flow
JIT

Producing products in smaller lots

Adoption of Development
continuous of various
flow types of simple
production automated
m/c to
facilitate
1963

continuous
flow 9
1

production 7
5 1999

Shortening 1 Development
of time for 9 of Global Body
changing 7 Line (GBL)
stamping 1
setups in all
plants
 Production Levelling based on Takt time
JIT

Adoption of Adoption of Better Adoption of Adoption of the

Sequence 10 days production automated new COMPASS
Tables order system equipment (Comprehensiv
(production instruction for issuing e process
planning) system production planning
Devised in instructions assembly

2002
1971

1980
1957

each simulation
9 process system)
1

6
6 1970

1974
Adoption 1 Adoption Adoption Building of 1
of a system9 of the daily of New order the Toyota 9
that issues6 order system Network 8
production0 system System 6
instructions
on JIT
basis
 When a problem is detected, production
Jidoka

lines stop and an alert is displayed

Adoption of Building in Completion Adoption of Elimination of
Andon quality of an automated water lead test
System for through use automated lines using in assembly
Visualisation of Poka-yoke engine line NC Machines plants
and robots

1998
1966

1980
1950

9
1

6
2 1962

1971
Adoption 1 Adoption Adoption Strengthening1
of andons 9 of full - work of a system if the system of9
linked to a5 control fixed building in 8
stop button5 position stop quality in- 2
in the process
assembly
process
 Separation of operator’s work and
Jidoka

machine’s work
Assignment Establishment Establishment Development
of each of standard of standardized of Visual &
operator to work wotk in all Virtual
multiple processes Communicatin
machines (V-Comm)
begin

1975

1996
1947

9
1

5
3 1963

1985
Innovation1 Adoption Establishment
9
in machining Of Concurrent of an efficient
5
automation multiple production
1 operations method for
dedicated lines
with a small
number of
operators
Thank You!!!
Journey Continues...