Toyota Production

System
By Srikrishna.NR (A31006420014)
 Vision
• Contribute to Indian industry and economy
through technology transfer, human resource
development and vehicles that meet global
standards at competitive price.
• Contribute to the well-being and stability of team
members.
• Contribute to the overall growth for our business
associates and the automobile industry.
 Mission
• Our mission is to design, manufacture and market
automobiles in India and overseas while
maintaining the high quality that meets global
Toyota quality standards, to offer superior value
and excellent after-sales service. We are dedicated
to providing the highest possible level of value to
customers, team members, communities and
investors in India.
7 Principles of Toyota
Production System
• Reduced setup time
• Small-lot production
• Employee Involvement and Empowerment
. Quality at the source
• Equipment maintenance
• Pull Production
• Supplier involvement
Toyota Production
System
 JUST-IN-TIME
* Produced according to what needed, when
needed and how much needed.
* Strategy to improve return on investment by
reducing inventory and associated cost.
* This process is driven by Kanban concept.
 KANBAN CONCEPT
Meaning- Sign, Index Card
> It is the most important Japanese concept opted by
Toyota.
> Kanban systems combined with unique scheduling
tools, dramatically reduces inventory levels.
> Enhances supplier/customer relationships and
improves the accuracy of manufacturing schedules.
> A signal is sent to produce and deliver a new shipment
when material is consumed.
> These signals are tracked through the refill cycle and
bring extraordinary visibility to suppliers and buyers .
 Just In Time Benefits
> Set up times are significantly reduced in the
warehouse.

> The flows of goods from warehouse to shelves are

improved.

> Employees who possess multiple skills are utilized

more efficiently.

> Better consistency of scheduling and consistency of

employee work hours.

> Increased emphasis on supplier relationships

 JIDOKA
> Jidoka (meaning ‘autonomation’)-a term used in Lean
manufacturing meaning "automation with a human
touch."

> It is a quality control process used in the Toyota

Production System which applies the following four
principles:

Detect the abnormality.

Stop.

Fix or correct the immediate condition.

Investigate the root cause and install a

countermeasure.
 Lean Manufacturing
> Most important concept of Toyota Production
System

> A management philosophy focusing on reduction

of the seven wastes to improve overall customer
value.
 Key Principles
> Pull processing> products are pulled from the consumer end
(demand), not pushed from the production end (Supply)
> Perfect first-time quality > quest for zero defects, revealing &
solving problems at the source
> Waste minimization > eliminating all activities that do not add
value & safety nets, maximize use of scarce resources (capital,
people and land)
> Continuous improvement > reducing costs, improving quality,
increasing productivity and information sharing
> Flexibility > producing different mixes or greater diversity of
products quickly, without sacrificing efficiency at lower
volumes of production
> Building and maintaining a long term relationship with
suppliers through collaborative risk sharing, cost sharing and
information sharing arrangements.
 Seven Ways To Improve Overall
Customer VALUE (MUDA)
> Transportation

> Inventory

> Motion

> Waiting time

> Over-production

> Processing Itself

> Defective Product (Scrap in manufactured

products or any type of business.)
Other Toyota Production
Concepts
Heijunka (Production Smoothing)
Kaizen (Continuous Improvement)
Poke-Yoke (to avoid inadvertent errors)
Andon (Signboard)
Mura,Muri
Heijunka (Production Smoothing)
> Heijunka is Japanese term that refers to a system of

production smoothing designed to achieve a more

even and consistent flow of work.

> Heijunka as a concept is closely related to lean

production and just in time manufacturing.

> A related visual scheduling board known as a heijunka

box is often used in achieving heijunka style
efficiencies.

> The use of heijunka as well as broader lean production

techniques helped Toyota massively reduce vehicle
production times as well as inventory levels during the
1980s.
 Kaizen
> Meaning- Continuous Improvement

> Kaizen refers to a workplace ‘quality’ strategy and related

to various quality-control systems.

> It aims to eliminate waste (defined as "activities that add

cost but do not add value").

> Kaizen is a daily activity whose purpose goes beyond

improvement. It is also a process that, when done

correctly, humanizes the work place eliminates overly

hard work (both mental and physical.

> It teaches people how to perform experiments using the

scientific method and how to learn to spot and eliminate
waste in business processes.
 Poke-Yoke
Poka-yoke (means "fail-safing" or "mistake-proofing"

avoiding (yokeru) inadvertent errors (poka)) is a

behavior-shaping constraint, or a method of
preventing errors by putting limits on how an
operation can be performed in order to force the
correct completion of the operation.
 Andon (Signboard)
> Andon is a manufacturing term referring to a signboard
incorporating signal lights, audio alarms, and text or other
displays installed at a workstation to notify management
and other workers of a quality or process problem.
>The alert can be activated manually by a worker, or may
be activated automatically by the production equipment
itself. Typically, it will incorporate both a visual indicator
and an audible alarm.
>An Andon system is one of the principle elements of the
Jidoka quality-control method pioneered by Toyota and
now part of the Lean methodology.
>It gives the worker the ability to stop production when a
defect is found, and immediately call for assistance.
>Work is stopped until a solution has been found out. The
alerts may be logged to a database so that they can be
studied as part of a continuous-improvement program.
>The system will typically indicate where the alert was
generated, and may also provide a description of the
trouble.
>Modern Andon systems can include text, graphics, or audio
elements.
>Audio alerts may be done with coded tones, music with
different tunes corresponding to the various alerts, or pre-
recorded verbal messages.
Mura,Muri
Mura
> Mura is a Japanese term for unevenness.
» It is also a key concept in the Toyota Production
System and is one of the three types of waste (Muda,
Mura, Muri) it identifies. Waste reduction is an effective
way to increase profitability.
Muri
> Muri is a Japanese term for overburden or
unreasonableness.
> It is also a key concept in the Toyota Production
System and is one of the three types of waste (Muda,
Mura, Muri) it identifies. Waste reduction is an effective
way to increase profitability.
> Muri can be avoided through standardised work .
 Conclusion

A Production System that is

steeped in the philosophy of the
complete elimination of all wastes
and that penetrates all aspects of
production with this philosophy in
pursuit of the most efficient
production method.