The document discusses the key principles of the Toyota Production System (TPS). It begins with a brief history of how TPS was developed by Toyota between 1948 and 1975. It then explains some core TPS concepts like just-in-time, jidoka, heijunka, and standardized work. It provides video examples for some concepts and discusses benefits like eliminating waste, quality products, and cost minimization. Classroom activities are also proposed to learn about jidoka and line balancing.

1. Guess the Car ??
INNOVA
FORTUNER
GLANZA
ETIOS LIVA

2. What is Common in above cars ?

3. Toyota Production System
(TPS)

4. Introduction to TPS ( Toyota Production System )

5. History of TPS
• The TPS organizes manufacturing and logistics for the automobile
manufacturer, including interaction with suppliers and customers.
• Taiichi Ohno and Eiji Toyoda, Japanese industrial engineers, developed the
system between 1948 and 1975.
• Originally called Just-in-time production,
• It builds on the approach created by the founder of Toyota, Sakichi Toyoda,
his son Kiichiro Toyoda, and the engineer Taiichi Ohno.

6. TPS – Toyota forklift example
INNOV
A
INNOV
A
VIDEO

7. Just in time - JIT
• Just in Time (JIT), as the name suggests, is a management philosophy that calls for
the production of
 what the customer wants,
 when they want it,
 in the quantities requested,
 where they want it,
 without it being delayed in inventory.

8. Just in time - JIT VIDEO

9. Jidoka
 Jidoka is about quality at source,
Or
built in quality;
 no company can survive without excellent quality of product and service and jidoka is the route through which this is
achieved.
The principle of Jidoka can be broken down into a few simple steps;
• Discover an abnormality
• STOP
• Fix the immediate problem
• Investigate and correct root cause

10. Jidoka VIDEO

11. Heijunka
 Heijunka (pronounced hi-JUNE-kuh)
 Japanese word that means “leveling.”
 When implemented correctly, heijunka elegantly – and without haste –
helps organizations meet demand while reducing wastes in production
and interpersonal processes.

12. Heijunka VIDEO

13. Standardized Work
• By documenting the current best practice, standardized work forms the baseline for kaizen
or continuous improvement.
• As the standard is improved, the new standard becomes the baseline for further
improvements, and so on. Improving standardized work is a never-ending process.
Basically, standardized work consists of three elements:
• Takt time - which is the rate at which products must be made in a process to meet
customer demand.
• The precise work sequence in which an operator performs tasks within takt time.
• The standard inventory, including units in machines, required to keep the process
operating smoothly.

14. Standardized Work VIDEO

15. Kaizen
• “Kaizen” refers to a Japanese word which means “improvement” or “change for the better”.
Kaizen is defined as a continuous effort by each and every employee (from the CEO to field
staff) to ensure improvement of all processes and systems of a particular organization.

16. Kaizen VIDEO

17. Benefits of TPS
Toyota Production System delivers the following key benefits:
• Empowers Teams
• Elimination of Waste
• Well defined responsibilities.
• Quality inherent in Toyota’s products
• Costs are kept to a minimum.
• Delivery is on time,
• Delivery to the expected standard, allowing
• Environmental concerns are shared by Toyota and its customers, from manufacturing through to recycling at
end-of-life
• Safety is Toyota’s constant concern – both for its employees and for those of its customers.

18. Toyota Production Documentary - Toyota Manufacturing Production
and Assembly at Toyota Factory
VIDEO

19. CLASSROOM ACTIVITY FOR TRAINER’S REFERENCE - Jidoka
VIDEO

20. CLASSROOM ACTIVITY FOR TRAINER’S REFERENCE –
Debottlenecking ( line balancing )
VIDEO

21. Thank - You

22. AGENDA
Activity Duration
Power point Presentation 1 Hour 30 mins
Case Study reading and discussion 1 Hour
Class room activities 2 Hour
Toyota Documentary 30 mins