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.
1897:- Sakichi Toyodadiversified 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 TPSin the USAwith 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
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 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Production Kanban is used to order production of the portion withdrawn by the subsequent process.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.
BENEFITS OF KAIZAN
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.
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.