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Key Concept in Toyota Production System and Their Own Thought

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Key concepts in Toyota Production System (TPS), building original unified man-machine system presented by Toshiaki Yanagida - Iwaki Production Systems Research Ltd.

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Key Concept in Toyota Production System and Their Own Thought

  1. 1. Copyright 2015 QuEST Forum. All Rights Reserved. 1 The Key concept in Toyota Production System and their own thought ― Building original unified man-machine system ― Iwaki Production System research Ltd. Toshiaki Yanagida QuEST APAC Tokyo BPC 4/15/2015 1
  2. 2. 2 Introduction • Welcome to Japan. • I present about TOYOTA Production System (TPS). – TPS was production system developed by TOYOTA and established through long period of their improvement. – TPS is famous for the name called “Lean manufacturing system” and well known in the world and many people study now.
  3. 3. TOYOTA Production System Mechanism of TPS ・Pull Production ・KANBAN(for Information ) ・Automatic stop mechanism ・Small lot production etc. three basic concepts (pillars) The thought in the undercurrent of TPS The background ・the environment ・their spirit 3
  4. 4. 4 What is TOYOTA Production System (TPS) • TPS is the total production system what TOYOTA made by themselves internally from TOYOTA establishment (1937). • There are three basic concepts (pillars) in TPS. –Just-in-time –Autonomation: This word is slightly different –Leveling from usual Automation.
  5. 5. 5 Just-in-time • To make and deliver what is needed, just when it is needed, and just in the amount needed. • (Originator) Mr.Kiichiro Toyoda‘s Spirit of foundation. He is a founder of TOYOTA. • He got an idea from supermarkets in USA. • Mechanism – Pull production system – Information communication by "KANBAN" etc.
  6. 6. 6 Autonomation < Jidouka > • Stop and notify abnormalities automatically and separate man-machine work“. not automation. • (Originator) Mr. Sakichi Toyoda’s spirit of invention. He is Mr.Kiichiro‘s father who invented "non-stop shuttle replacement expression Toyoda automatic loom (type G)". • "Automation" goes with loss. • Mechanism – Automatic stop mechanism against abnormality – the line stop rule. etc.
  7. 7. 7 Leveling < Heijunnka > • Leveling the type and quantity of production over a fixed period of time. • (Originator) Mr.Taiichi Ouno who is actual TPS originator and he thought leveling so strong. • When the production flow will be much fluctuated, waste should be much bigger. • Mechanism – Small lot production. – Single setup (changeover). etc.
  8. 8. 8 The background why TPS was born (the environment) • TOYOTA was very late departure company in comparison with an overseas manufacturer. • The Japanese market size at that time was one-50th of the United States. • Almost none of Infrastructure (technics related company) was maintained.
  9. 9. 9 The background why TPS was born (their spirit) • They didn't want to follow European and American style. • They wanted to manufacture cars by their original techniques.
  10. 10. 10 The thought in the undercurrent of TPS • A person works willingly by oneself. So we shall utilize these persons. • The quantity to sell goods is limited. So we shall work with the limited quantity. • The quantity involves loss. So we shall think how to stop loss rather than quantity at first.
  11. 11. 11 Way of thinking of quality improvement in TPS • It's made in the flow. • Setting and obeying of standard work (work procedure, cycle time and the number of holdings). • Pursuit of root cause ( 5 Why), measure and level development.
  12. 12. TOYOTA Production System Mechanism of TPS ・Pull Production ・KANBAN(for Information ) ・Automatic stop mechanism ・Small lot production etc. three basic concepts (pillars) ・Just-in-time ・Autonomation <Jidouka> ・Leveling <Heijunnka> The thought in the undercurrent of TPS ・A person works willingly by oneself. ・The quantity to sell of goods is limited. ・The quantity involves loss. The background ・the environment ・their spirit Thorough Exclusion of Waste 12
  13. 13. 13 Future TPS • TPS is a production system suitable for multi- objective production. • There is accumulation of the technology, know- how and tools for the past 70 years. ⇒ TPS will grow in future and will spread. The important thing is that not only “ the structure of production system ” but also “ factory culture and their mind ” is improved together.
  14. 14. 14 My Expectation • "Exclusion of waste of the material and the energy of the person" is also important thing for the continuation of the global environment. • I hope that TPS is useful in the various parts of the worlds. Thank you.

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