1. Toyota Production System focuses on managing brilliant processes with average people to achieve brilliant results, unlike competitors who rely on brilliant people to manage broken processes. 2. World Class Manufacturing introduced in 1984 focuses on continuous improvement, zero defects, breakdowns, waste, and accidents through techniques like kaizen and following a philosophy of innovation and gradual improvement. 3. The Toyota Production System originated in Japan and focuses on tools less than teams, consistent leadership, doing more than analyzing, and a deeper business philosophy understanding people and motivation.

1. Toyota Production System
As per Fujio Cho
We get brilliant results from average people managing brilliant processes – while our
competitors get average or worse results from brilliant people managing broken processes.

2. Introduction to World Class Manufacturing
Introduced by: Hayes and Wheelwright; Year 1984
Use of best practices -> Superior performance
World Class -> Best in class
Based on Kaizen
Focus on: - Zero breakdown = High Reliability
Zero defects = High Quality
Zero accident = Low waste

3. Fundamental strategy of WCM
Innovation: -
1. Top down approach
2. Large investments
3. Movement in Vertical direction -> Meeting needs of market & functional areas
Kaizen: -
1. Continuous improvement
2. Gradual
3. Movement in Horizontal direction -> Daily improvements

4. Characteristics of WCM
0 100%
Zero accident
Zero breakdown
Zero defects
Zero scrap
Voice of customer is heard till last level
Continuous improvement via loss eradication People drive change
No type of waste. Motivating environment
Methods of improvement are applied strictly All faults are visible

6. Introduction to Toyota Production System
Originated from Japan.
High level of operational performance.
Focus on tools < Focus on team
Consistent leadership.
Invest more time in doing and less in analyzing.
Reason for success: Deeper business philosophy based on its understanding of people and
human motivation.

7. 4 P model of Toyota Production System
Problem Solving
People and Partners
Process
Philosophy

8. Important tools of Toyota Production System
JIT
Kaizen
Jidoka
One piece flow

9. TPS + Lean System
Running the machines at optimal throughput level to: -
1. Avoid wastage due to overproduction
2. Avoid large volume of inventory
3. Remain unaffected by demand fluctuation
4. To reduce irregular working hours.

10. Competitors of Toyota
Ford
General Motors
Volkswagen
Nissan
Honda

11. Thank you