Toyota is a Japanese automaker headquartered in Japan since 1937. It has over 71,000 employees and operates globally in over 170 countries. Toyota uses a philosophy of continuous improvement called Toyota Production System or Lean Manufacturing. It focuses on just-in-time production, continuous flow, and elimination of waste through standard processes and employee engagement. Toyota also focuses on developing local supply chains and manufacturing bases in regions around the world to build automobiles and parts locally.

1. TOYATA
PRESENTED BY
ALOK RANJAN
GROUP NO.4

2.  Headquartered in Japanda in 1937
 Founded by Kiichiro Toyda
 Revenues 18.9 trillion Yen in 2010
 71,116 employees
 Operations in North America, Latin
America, Europe, Africa, Asia,
Oceania and Middle East

3. The Four Steps of TJI
Step 4: FOLLOW UP Step 1: PREPARE
WORKER
Action Plan
Major Steps
Key Points
Check
Reasons Do
Step 3: TRY OUT Step 2: PRESENT
PERFORMANCE OPERATION

4.  Top Down Directive that this is the new way.
 Bottom-up involvement in concrete projects
with clear results.
 Develop internal experts through learning by
doing.
 Expert sensei to guide the process and teach.
 Learning philosophy: every project, activity, is a
chance to learn.
 Start with value stream transformation projects.
 Build on successes to transform broader
organization and culture over time---YEARS!

5. Establish a local Establish JVs with
Build Auto parts
sales network and local players and
manufacturing
launch brand build automobiles
bases
promotion there

7.  During the almost 50 years since they first
began exports, Toyota vehicles have found
their way to over 170 countries and regions
throughout the world
 Currently there are 52 bases in 27 different
countries and regions.
 In addition, there are design and R&D bases
in seven locations overseas

8. T
1 2 3 4 5 6 7
8 9 10 11 12 13 14
STOP BUTTON
(STOP THE L I E AUTHOR I Y )
N T STOP BUTTON
(STOP THE L I E AUTHOR I Y )
N T
5
4 Abnormality
Station 5
Team Leader

9. ORGANIGATION STRUCTURE OF TOYATA HR
Team Size
Team Member
{5-8}
Kaizen
Team Leader
{3-4}
Group Leader
{5-8}
Asst. Manager
{ 4 - 10 }
Manager
Source: Bill Costantino, former group leader, Toyota, Georgetown.

10.  Job Instruction Training is designed to teach
people how to do a particular job by:
 Hearing (what to do)
 Seeing (how it is done)
 Using (what was learned)
 Saying (what was learned)
 Doing (the task)


11. Downstream prTTTTTTocesses TTKKFNESADNFTTTTwithdraw wha
they need when they need it.
Empties + withdrawal
kanban
Empties +
production kanban
A
B
C
D
E
PULL
F
Customer Plant
New product G
H
Needed
Components + kanban
Supplier Plant
Preceding processes replenish what is taken away.

12. General Manager and VP Level
Concentrate on Business Planning
and Policy Improvement. Tools:
Hoshin Planning & TBP
Manage r Leve l
Focus on Shop Floor and
Systems Improvement.
Tools: Visual Factory & TBPT
TBP
Team Leade r and Group Leade r
Manage Standardized Work, Process
Improvement and Develop Problem
Solving Skills . Tools: FMDS, TBP & OJD
Team Membe r
Focus on Fundamental Skills & Standardized Work
Tools: Skills Trainin g, Job Instruction, Standardized Work
and 5-S

13.  Jumping from “problem” to “solution” without
clear understanding and analysis
PROBLEM
SOLUTION

16. THANK YOU