Overview of Toyota Production System

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