Taiichi Ohno introduced the Toyota Production System (TPS) which focused on eliminating waste to reduce costs. TPS has two parts: technical aspects like Just-In-Time (JIT) production and human/people aspects. JIT production is based on only producing what is needed, when it is needed, in the needed quantity based on customer demand pulling parts through the process rather than a push system. This pull system is facilitated through Kanban cards that visually signal production needs and parts delivery. Ohno identified seven types of waste that TPS aims to eliminate through continuous improvement approaches like Kaizen.

1. Taiichi Ohno & the Toyota Production System Presented by: Gaurav Gupta

2. Introduction Toyota’s History Toyota’s first export to U.S. was not successful In 2004 Toyota’s net earning was double the combined net earnings of automobile majors.

3. Taiichi Ohno Born in 1912 in China. He introduced JIT and Kanban system. In 1975, Ohno became the Vice President of Toyota. Died in 1990 in Toyota city.

4. The Toyota Production System(TPS ) Collaborative effort of Ohno , Sakichi , Kiichiro and Eiji. Focus was on ‘Reduction of cost through elimination of the waste. TPS consists of two parts : ‘ the hard or the technical part’ and ‘ the soft or people related part’

5. Just In Time (JIT ) JIT was the foundation of the TPS. Underlying Principle : “ Produce only the necessary products, at the necessary time and in the necessary quantity.” JIT governed Toyota’s buy strategy.

6. The concept of JIT was based on the ‘ Reverse Reasoning’ Based on the ‘PULL’ system of manufacturing and not on ‘PUSH’ system. Complexity of the process gave birth to the ‘Kanban System.’ DEMAND ASSEMBLY DELIVERY OF PARTS SUPPLY BY SUPPLIER

7. The word Kan means "visual" in Japanese and the word "ban" means "card". So Kanban refers to "visual cards".

8. What Are The Benefits of Kanban? Reduces inventory and product obsolescence Reduces waste and scrap Provides flexibility in production Increases Output Reduces Total Cost

9. KAIZEN Means ‘continuous improvement’. Eliminating all ‘waste’. Observation. Understand the problem. Commitment of the management. Poka-yoke or error proofing.

10. Pre-requisites for kaizen Discard conventional fixed ideas. Don’t make excuses. Correct it right away , if you make a mistake. Seek the wisdom of ten people rather than that of one. Think of how to do it , not why it cannot be done. Ask ‘Why?’ five times.

11. HUMAN ELEMENTS Team work Safety work place Visible control Conduct production activities .

12. JIDOKA Andon cord Training & development Physical fitness Preference to engineers.

13. Ohno’s Seven Wastes Defects Over Production Waiting Transporting Movement Inappropriate Processing Inventory

14. Push System Raw material Parts Manufacture Assembly Product

15. Pull System Demand Assembly Parts Supply Raw Materials

16. Conclusion Benefits Challenges

17. Thank You