Toyota Production System

by : Iskandar Syahril Ibrahim Sukri (P50078)

 Toyota Motor Co. Ltd was established by Kiichiro Toyoda in 1937 as a
spin-off from Toyoda Automatic Loom Works
Toyota launched its first passenger
car in 1947

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FOUNDER OF TPS
'Toyota Production System’ was established in 1970 by Taiichi Ohno. B
ased on the principles of JIDOKA, JUST-IN-TIME and KAIZEN, REDUCT
ION OF INVENTORIES and DEFECTS in the plants of Toyota and its sup
pliers

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•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 (stan
dardize), 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

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Another thing to consider: Most improvement methodologies concentra
te on reducing labor hours. Unfortunately, touch labor is generally a ve
ry small percentage of the total cost of most modern products.
There is, however, another way to look at this: If you push the process
down through all your suppliers, the only factors that are not people’s “
labor” are the ore in the ground, oxygen in the air, water in the streams
, and sources of energy. So the total people costs usually are a large p
ercentage of the final cost. And even though touch labor in assembly i
s not a great cost driver, it is often a significant time driver, which (as a
component of OODA loops) may have a greater impact on competitiven
ess than just cost.
-Autonomous automation for 100% zero defect production

JIDOKA = AUTONOMATION = AUTOMATION WITH HUMAN INTELLIGENC

E

4 Principles of Autonomation
1. Detect the abnormality.
2. Stop.
3. Fix or correct the immediate condition.
4. Investigate the root cause and install a countermeasure.
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JIT- philosophy of continuous improvement that puts emphasis on prev
ention rather than correction, and demands a company wide focus on
quality.
JIT- operational management approach to world class manufacturing.
JIT- production is based on demand
Just in Time is delivery of the needed amount at the right time:
•buffer free
•store free
•kanban
•involvement of the supplier in the kanban
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Advantages of going TPS:
Companies that pursue and emulate TPS best practices have seen muc
h success as a result of this highly effective manufacturing philosophy.
Some of the benefits include:
•Identify and enhance customer perceived value
•Decrease waste and cost in the manufacturing process
•Improve product quality and on-time delivery
•Develop a competitive world class manufacturing operation

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