THE TOYOTA PRODUCTION SYSTEM

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 THE TOYOTA PRODUCTION SYSTEM

HOW TOYOTA CAME INTO PROMINENCE

• The Oil Crisis of 1973

• ‘Japanese Invasion’
• Better Quality
• Better Mileage
• Lower Maintenance
• Lower Prices

• Discussion and Inquiry

• Manufacturing Excellence

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 THE TOYOTA PRODUCTION SYSTEM

TOYOTA PRODUCTION SYSTEM

THE DEVELPOMENT

• Ford’s book/ visit to Ford’s plants

• Limited resources

• Small market base

• Need for variety

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 THE TOYOTA PRODUCTION SYSTEM

TOYOTA PRODUCTION SYSTEM

THE CONCEPTS
• 3Ms - Muda, Muri, Mura
• Just In Time
• Heijunka
• Continuous Process Flow

• Standardisation
• Jidoka
• Kaizen
• Five Ss
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 THE TOYOTA PRODUCTION SYSTEM
3Ms
Muda, Muri, Mura

• Muda – Waste ->

• Muri – Strain
• Safety
• Quality
• Breakdowns
• Mura - Unevenness

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 THE TOYOTA PRODUCTION SYSTEM

Just In Time
Receipt materials at the time of requirement in the required
quantity
• Pull Systems
• Kanban

• Advantages of Just in Time

• Reduces the costs of maintaining inventory
• Reduces space required for storing inventory
• Reduces risk of loss due to obsolescence
• Reduces overproduction

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 THE TOYOTA PRODUCTION SYSTEM

Heijunka
Production Leveling – An even distribution of product variety
and volume over time

• Advantages of Heijunka approach to planning

• Provides a very stable foundation for other TPS
activities
• Reduces the strain on resources
• Reduces inventory
• Achieves a balanced mix of FG inventory

• Illustration
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 THE TOYOTA PRODUCTION SYSTEM

Continuous Process Flow

Transfer of material between process in the least possible time
and minimum inventory in between processes

• Advantages of continuous process flow

• Encourages implementation of other TPS tools
• Exposes inefficiencies in the system faster
• Reduces lead time
• Frees up capital by reducing in-process inventory
• Reduces floor space requirement

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 THE TOYOTA PRODUCTION SYSTEM

Standardization
Determining, documenting in detail and applying in relevant
places the best approach to accomplishing any task

• Advantages of standardization
• Ensures quality of output by giving consistency to
the process
• Provides a stable foundation for continuous
improvements
• Improves flexibility in utilization of manpower

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 THE TOYOTA PRODUCTION SYSTEM

Jidoka
Detect defects and take corrective action before any defective
output passes downstream

• Andon: Audio/ visual signal

• Poka-Yoke: Error prevention

• Advantages of Jidoka
• Ensures quality in output
• Increases productivity
• Saves reworking costs

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 THE TOYOTA PRODUCTION SYSTEM

Kaizen
Continuous Improvement

• Standardize/ stabilize an operation

• Measure the performance parameters of the operation
• Find ways to improve performance
• Stabilize the operation at the new performance levels
• Repeat the cycle of measurement, improvement and
stabilization

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 THE TOYOTA PRODUCTION SYSTEM

Five Ss

• Seiri - Sorting
• Seiton - Store in a systematic manner
• Seiso - Clean the tools and the surroundings
• Seiketsu - Standardizing work techniques
• Shitsuke - Discipline to sustain the above activities in
the long run

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 THE TOYOTA PRODUCTION SYSTEM

Non-Heijunka Approach to Production Planning

DAY 1 2 3 4 5 6 7
F1 XYZ XYYY XY XZZZ ZZ Y XZZY

F2 BBB BBB BSSS SSSSSS SSSSM SMMM MMM

Heijunka Approach to Planning

DAY 1 2 3 4 5 6 7
F1 XZY XZY XZY XZY XZY XZY XZY

F2 BMSS BMSS BMSS BMSS BMSS BMSS BMSS

back
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 Activities that fail to add value

• Defects
• Overproduction
• Transportation of goods
• Waiting
• Inventory
• Motion of people
• Over Processing
• Unutilized Skill

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