TOYOTA PRODUCTION SYSTEM

TOYOTA PRODUCTION SYSTEM

TOYOTA PRODUCTION SYSTEM

The Toyota Production System is a philosophy of manufacturing that was created by the Toyota Corporation. The Toyota Production System or TPS, has come to be known as a term that is synonymous with Lean Manufacturing. Lean manufacturing aims to improve the manufacturing process by eliminating wastes in all their forms. The TPS names seven wastes specifically and collectively calls these wastes "Muda." Also called "The Seven Deadly Wastes" the muda as defined by Toyota includes the following: over-production, motion (of operator or machine), waiting (of operator or machine), conveyance, processing itself, inventory (raw material) and correction (rework and scrap).

Not only are processes sped up when waste is eliminated through TPS but the quality of the product is better. This means that the customer benefits from the TPS process just as much, if not more, than the manufacturer benefits. Toyota has long benefited from their innovations in the world of lean thinking and in 2007 became the largest car manufacturer in the world. Although the principles of TPS can theoretically be applied universally, no manufacturer has yet to master the processes the way that Toyota has.

The Toyota Production System has come to include a great number of different concepts and methodologies. As different companies will find it useful to utilize different strategies for the implementation of their Toyota Production System a brief list and definition of common terms is listed below:

Just In Time (JIT) - JIT is an inventory strategy that a company may chose to implement in order to improve the return on investment of a business by reducing inventory and the costs associated with carrying unsold goods.

Jidoka (Autonomation) - Jidoka is a Japanese word that refers to the process of creating an automated production line that also includes a human touch. Machines perform with Autonomation when they are programmed to stop producing in the case of an error. It is then the human who identifies and resolves the problem.

Kaizen (Continuous Improvement) - This Japanese term refers to the process of gradual change for the better. Employees are encouraged to provide input and improve the processes that they are over thereby making their jobs more enjoyable and the production line more efficient.

Andon - This term refers to a method used in visual control and when translated into English means "Signboard." Visual control is a process that uses visual cues such as graphics to constantly illustrate to workers just how the production process and work environment should flow.

Pokayoke - The process of fool-proofing or mistake-proofing a system by identifying the cause of defects or errors and putting a plan in place to prevent such inadvertent errors from occurring again.

Muda - The term muda is often accompanied with a list of seven different wastes or "deadly wastes" that a company looking to implement lean manufacturing techniques is trying to eliminate. (The terms "Muri" and "Mura" refer respectively to the overburden and unevenness that accompanies the carrying of the unnecessary wastes).

Since Toyota production system has been created from actual practices in the factories of Toyota, it has a strong feature of emphasizing practical implications. This system can play a great role in the task of improving the constitutions of the companies world-wide

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