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Toyota Motor Corporation -  with an overview of “ TKML ” and  “ Toyota Production System ” Welcome
Corporate Profile <ul><li>World's third largest automaker  </li></ul><ul><li>Global sales totaled 6.17 million units in 20...
History <ul><li>Toyota Motor Co. Ltd was established by Kiichiro Toyoda in 1937 as a spin-off from Toyoda Automatic Loom W...
TOYOTA GLOBAL VISION  <ul><li>Be a driving force in global regeneration by implementing the most  advanced environmental t...
Toyota’s sales in comparison to other manufacturers  (in‘000) * Data for 2002
Toyota Kirloskar Motors Ltd.
Toyota Kirloskar Motors Ltd <ul><li>Established in 1997 </li></ul><ul><li>Started as a 74:26 partnership between Toyota an...
Indian Operations: <ul><li>TKML manufactures three models in India namely Qualis Corolla and Camry </li></ul><ul><li>TKML ...
The Qualis Story.. <ul><li>Launched in 2000 </li></ul><ul><li>A MUV marketed as easy to ride spacious family car </li></ul...
The Qualis story contd… <ul><li>New Qualis launched recently  </li></ul><ul><li>Faces competition from future entrants lik...
Toyota Production Systems  an overview of  Jidoka ,  Just-in-time  and  Kaizen ,  Reduction of inventories  and  Defects
TPS Myths and Realities <ul><li>Tangible recipe for success </li></ul><ul><li>Management project and program </li></ul><ul...
Elements of TPS <ul><li>The SMED Program. </li></ul><ul><li>Highlight Problems (Jidoka). </li></ul><ul><li>Gradual Elimina...
Toyota’s Management Philosophy
Focus on JIDOKA
Separately positioned Processing
Continuous Flow Processing
Traditional “Buffered” Supply Chain Assembler 2 nd  Tier 1 st  Tier Flow of Production Flow of Information Customer Demand
The Just-in-Time Supply Chain Toyota 2 nd  Tier 1 st  Tier Flow of Production Flow of Information Customer Demand
Expectations from Suppliers <ul><li>Frequent deliveries. </li></ul><ul><li>Hours (not days) lead time. </li></ul><ul><li>R...
What’s in it for a supplier? <ul><li>Continuous improvement </li></ul><ul><li>Design for manufacturability </li></ul><ul><...
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Toyota Production System[1]

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Transcript of "Toyota Production System[1]"

  1. 1. Toyota Motor Corporation - with an overview of “ TKML ” and “ Toyota Production System ” Welcome
  2. 2. Corporate Profile <ul><li>World's third largest automaker </li></ul><ul><li>Global sales totaled 6.17 million units in 2002 </li></ul><ul><li>Toyota has 45 manufacturing companies in 26 countries </li></ul><ul><li>Toyota employs 264,000 people worldwide </li></ul><ul><li>Markets vehicles in170 countries </li></ul><ul><li>Net sales 16,054.2 billion yen </li></ul>
  3. 3. History <ul><li>Toyota Motor Co. Ltd was established by Kiichiro Toyoda in 1937 as a spin-off from Toyoda Automatic Loom Works </li></ul><ul><li>Toyota launched its first small car (SA Model) in 1947 </li></ul><ul><li>Production of vehicles outside Japan began in 1959 at a small plant in Brazil </li></ul><ul><li>'Toyota Production System’ was established in 1970 by Taiichi Ohno. Based on the principles of Jidoka , Just-in-time and Kaizen , Reduction of inventories and Defects in the plants of Toyota and its suppliers </li></ul>
  4. 4. TOYOTA GLOBAL VISION <ul><li>Be a driving force in global regeneration by implementing the most advanced environmental technologies </li></ul><ul><li>Creating automobiles and a motorized society in which people can live safely, securely and comfortably </li></ul><ul><li>Promote the appeal of cars throughout the world and realize a large increase in the number of Toyota fans . </li></ul><ul><li>Be a truly global company that is trusted and respected by all peoples around the world </li></ul>
  5. 5. Toyota’s sales in comparison to other manufacturers (in‘000) * Data for 2002
  6. 6. Toyota Kirloskar Motors Ltd.
  7. 7. Toyota Kirloskar Motors Ltd <ul><li>Established in 1997 </li></ul><ul><li>Started as a 74:26 partnership between Toyota and Kirloskar </li></ul><ul><li>At present the stake of TMC is 99% </li></ul>
  8. 8. Indian Operations: <ul><li>TKML manufactures three models in India namely Qualis Corolla and Camry </li></ul><ul><li>TKML plans to introduce the Land Cruiser and other international models over time </li></ul><ul><li>Toyota Kirloskar Auto Parts’ (TKAP) is a 100-per cent export oriented auto transmission plant at Bidadi, Karnataka. </li></ul>
  9. 9. The Qualis Story.. <ul><li>Launched in 2000 </li></ul><ul><li>A MUV marketed as easy to ride spacious family car </li></ul><ul><li>40% of MPV segment </li></ul><ul><li>Competitors:Scorpio </li></ul><ul><li>TATA Sierra ,Safari </li></ul>
  10. 10. The Qualis story contd… <ul><li>New Qualis launched recently </li></ul><ul><li>Faces competition from future entrants like GM Panther ,M&M Rexton Ford Everest </li></ul><ul><li>To be replaced with a new intl model </li></ul>
  11. 11. Toyota Production Systems an overview of Jidoka , Just-in-time and Kaizen , Reduction of inventories and Defects
  12. 12. TPS Myths and Realities <ul><li>Tangible recipe for success </li></ul><ul><li>Management project and program </li></ul><ul><li>Set of tools for implementation </li></ul><ul><li>System for production floor </li></ul><ul><li>Way of thinking </li></ul><ul><li>Management philosophy </li></ul><ul><li>Focus on total customer satisfaction </li></ul><ul><li>Environment for teamwork and improvement </li></ul>Myths Realities
  13. 13. Elements of TPS <ul><li>The SMED Program. </li></ul><ul><li>Highlight Problems (Jidoka). </li></ul><ul><li>Gradual Elimination of Waste. </li></ul><ul><ul><li>Continuous Improvement (Kaizen), Root-Cause Analysis (5-whys?) and Fool-proofing (Poka-Yoke), 5-S. </li></ul></ul><ul><li>Cross-Trained Workers. </li></ul><ul><li>Just-In-Time Production. </li></ul><ul><li>Stable Production Schedules (Heijunka) </li></ul>
  14. 14. Toyota’s Management Philosophy
  15. 15. Focus on JIDOKA
  16. 16. Separately positioned Processing
  17. 17. Continuous Flow Processing
  18. 18. Traditional “Buffered” Supply Chain Assembler 2 nd Tier 1 st Tier Flow of Production Flow of Information Customer Demand
  19. 19. The Just-in-Time Supply Chain Toyota 2 nd Tier 1 st Tier Flow of Production Flow of Information Customer Demand
  20. 20. Expectations from Suppliers <ul><li>Frequent deliveries. </li></ul><ul><li>Hours (not days) lead time. </li></ul><ul><li>Rapid response capability (not from stocks). </li></ul><ul><li>Delivery to assembly line at the right time in the right sequence without inspection. </li></ul><ul><li>Reliability (quality and timing). </li></ul>
  21. 21. What’s in it for a supplier? <ul><li>Continuous improvement </li></ul><ul><li>Design for manufacturability </li></ul><ul><li>A Stable Manufacturing Environment </li></ul><ul><li>(Steady production volume) </li></ul><ul><li>Leaner Processes </li></ul><ul><li>(Cost/Flexibility/Quality) </li></ul><ul><li>Profits </li></ul>
  22. 22. Thank you
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