The document discusses concepts from the Toyota Production System including kaizen (continuous improvement), the seven types of muda (waste), and strategies to minimize waste and lead time. It explains that muda includes overproduction, waiting, transportation, unnecessary processing, inventory, motion, and defects. The Toyota system aims to continuously improve processes by identifying and eliminating muda to maximize value added work and minimize costs in order to better satisfy customers.

1. Toyota Production System KAIZEN NAEEM BHAI

2. Change Better Make it better ( Improvement )

3. Getting Started What is a Manufacturing Company ? Make good quality products Selling to Customer Earn Profit Guarantee employee’s better life Bring prosperity to people

5. Cost,Profit & Price Profit Cost Selling Price Selling Price = Cost + Profit Cost & Profit Profit = Selling Price - Cost Selling Price (Rs) How to earn more profit? Increase the selling price Reduce the cost

6. Cost,Profit & Price Material cost Purchased Parts cost Other cost Facility cost The expenses depend upon the method of manufacturing Every company is same (No big difference in a cost components) There is a difference depending on industry Cost Cost (Expense) Based on TPS Product Manufacturing and the cost KAIZEN Minimum Investment & Maximum Profit

7. TPS What is MUDA (Waste)? Identified by Tenchi Ohno-Japan Waste is the use of any material or resource beyond what the customer requires and is willing to pay for.

8. TPS MURI (overburden) MURA (unevenness) MUDA (waste) Value- Added Work Motions of Worker MUDA= Non Value-Added Work Non Value-Added Work Customer pays money only for Value-Added Work

9. TPS waste of overproduction Waste of waiting Waste of transportation Waste of processing itself Waste of inventory Waste of movement Waste of making defective products 7 Types of Muda

17. TPS Over Burden Adding work without eliminating Muda Understanding of Adding Work Eliminating Muda through Kaizen Adding Work in Saved Time = work MUDA work work MUDA MUDA Adding Work No Over Burden work work MUDA KAIZEN MUDA work MUDA = Adding Work

18. TPS Minimize Lead Time Minimize Non Processing Time Many types of MUDA will be highlighted when we minimize the Non Processing Time Lead Time = Processing Time + Non Processing Time = + = LEAD TIME Lead Time : time required to process from start to end (i.e. from raw material processing till packing goods)

19. Eliminate all MUDA from work site(NO.1) Injection Shop= Ground Floor Assembly Shop= 1 st Floor Ground Floor Ground Floor+ Use of Trolley [Before] [After]

20. Eliminate all MUDA from work site(NO.2) ﾗｲｾﾞﾝ ﾋﾞﾃﾞｵ Make Process Flow Video-3 Video-4 punching Jig Assy Jig

22. Let’s move towards continual Kaizen Thank You