The Toyota Production System (TPS) was developed by Toyota to improve productivity after World War II. [1] Taiichi Ohno drew upon ideas from the West and experimentation to develop TPS between 1948-1975. [2] TPS focuses on just-in-time production, built-in quality control through jidoka, and the elimination of waste through concepts like kanban. [3] The goals of TPS are to design out inconsistency and waste, have flexible production processes, and encourage participation to reduce defects and inventory.

1. TOYOTA PRODUCTIONTOYOTA PRODUCTION
SYSTEM (TPS)SYSTEM (TPS)
Submitted by:
Sagar A Hasmanis (R. No. 36)
Tamanna Yadav (R. No. 46)
Chander Shekhar (R. No. 10)
Abhishek Gopal (R. No. 01)

2. INDEX
Toyota story
Essence of TPS
TPS

3. Taiichi Ohno (1912 – 1990)
Father ofToyota Production System

4. History
 Moving assembly line was the ideal model on which Toyota
based their production system back in the 1940s
 Started lean manufacturing on the shop floor, after World
War II as a solution to a very real and pressing problem
 After World War II when Japanese industry was decimated,
the Toyoda family decided to extend Toyota Automatic
Loom company to start an automotive company. They had
some cash but did not have the infrastructure
 Under these conditions, Taiichi Ohno was given the
assignment of catching up with American companies in
productivity at a time when they were behind

5. HistoryHistory
Ohno drew upon a number of ideas from the West
and a lot of experimentation to ultimately develop
TPS
Quality problem at Toyota led to introduction of
concept of “JIDOKA” – built in quality
After the 1973 oil crisis, Japan’s economy collapsed
to zero growth. Even Toyota Motor Company
suffered losses greater earnings were sustained in
1975, 1976 and 1977 than at other Japanese
companies – which made Japan follow Toyota’s style
naming it as Toyota Production System
Taiichi Ohno, Shigeo Shingo and Eiji Toyoda
developed the system between 1948 and 1975

6. TPS Concepts

7. TPS ConceptsTPS Concepts
1. JIDOKA: highlighting problems
 Means that a machine safely stops when the
normal processing is completed
 Since a machine automatically stops when
processing is completed / when a problem
arises and is communicated via the "andon
(problem display board)," operators can
confidently continue performing work at
another machine, as well as easily identify the
problem cause and prevent its recurrence.

8. Concept of “Jidoka”Concept of “Jidoka”

9. TPS ConceptsTPS Concepts
2. JUST IN TIME: complete elimination of
waste
 When a order is received, production instruction
must be issued to the beginning of the production
line as soon as possible
 The assembly line must be stocked with small
numbers of all types of parts so that any kind of
vehicle ordered can be assembled
 The assembly line must replace the parts used by
retrieving same number of parts from the parts-
producing process
 The preceding process must be stocked with small
no. of all types of parts and produce only the no. of
parts required in next process

10. http://www.toyota.co.jp/en/vision/production_system/video.html

11. Kanban systemKanban system
Unique production control method
Idea borrowed from super markets so
called “super market method”
when a process goes to the preceding
process to retrieve parts, it uses kanban
signs to communicate what parts have
been used
Reduces excess production

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18. GOALS OF TPSGOALS OF TPS
•Design out overburden(muri), inconsistency(mura)
& eliminate waste(muda)
• Process of production is as flexible as possible
• Follows 5 s approach- sieri(sort), seiton(set in
order), seiso(shine), seiketsu (standardize),
shitsuke(sustain)
• Participation of all employees in the work process
• Elimination of imperfection or problem so as to
reduce inventory
• Systems thinking- tools & techniques are highly
interdependent

19. OUTCOME OF TPSOUTCOME OF TPS
•Reduction of lead time to a great extent
• Improvement of quality
• One of ten largest companies in the world
• Largest car manufacturer
• Low cost
• Fast response

20. Toyota’s spirit of “ making things” is being spread through out the world
as
“The Toyota way”