Toyota Production System

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The Toyota Production System (TPS) (トヨタ生産方式) is the philosophy organizing manufacturing and logistics at Toyota, including the interaction with suppliers and customers. TPS is known more generically as Lean manufacturing. It was largely created by three men: the founder of Toyota, Sakichi Toyoda, his son Kiichiro Toyoda, and the engineer Taiichi Ohno who drew heavily on the work of W. Edwards Demming and the writings of Henry Ford. The main goal of the TPS is to eliminate waste (無駄, Muda). There are 7 kinds of waste targeted in the TPS.

  1. Over-production
  2. Motion (of operator or machine)
  3. Waiting (of operator or machine)
  4. Conveyance
  5. Processing Itself
  6. Inventory (raw material)
  7. Correction (rework & scrap)

Toyota was able to greatly reduce leadtime and cost using the TPS, while improving quality at the same time. This enabled it to become one of the ten largest companies in the world. The TPS is a classic example of the Kaizen approach to productivity improvement. Due to this stellar success of the production philosophy many of these methods have been copied by other manufacturing companies.

Contents

[edit] Commonly used terminology in TPS:

  • Just In Time (ジャストインタイム) (JIT)
  • Jidoka (自働化) (English: Autonomation - automation with human intelligence)
  • Heijunka (平準化) (English: Production Smoothing)
  • Kaizen (改善) (English: Continuous Improvement)
  • Poka-yoke (ポカヨケ) (English: fail-safing - to avoid (yokeru) inadvertent errors (poka))
  • Kanban (看板, also かんばん) (English: Sign, Index Card)
  • Andon (アンドン) (English: Signboard)
  • Muda (無駄, also ムダ) (English: Waste)

[edit] References

  • Ohno, Taiichi (1995), Toyota Production System: Beyond Large-scale Production, Productivity Press Inc., ISBN 0-915299-14-3.
  • Yasuhiro Monden (1998), Toyota Production System, An Integrated Approach to Just-In-Time, Third edition, Spring, ISBN 0-412-83930-X.
  • Jeffrey Liker (2003), The Toyota Way: 14 Management Principles from the World's Greatest Manufacturer, First edition, McGraw-Hill, ISBN 0-07-139231-9.
  • Womack, James P. and Jones, Daniel T. (2003), Lean Thinking: Banish Waste and Create Wealth in Your Corporation, Revised and Updated, HarperBusiness, ISBN 0-7432-4927-5.
  • Womack, James P., Jones, Daniel T., and Roos, Daniel (1991), The Machine That Changed the World: The Story of Lean Production, HarperBusiness, 2003, ISBN 0-06-097417-6.
  • Shingo, Shigeo (1989) A Study of the Toyota Production System from an Industrial Engineering Viewpoint (Produce What Is Needed, When It's Needed), Productivity Press, ISBN 0-915299-17-8. (This refers to the English version; the Japanese version was published in 1981, but the ISBN is unknown)
  • Spear, Steven, and Bowen, H. Kent (September 1999), "Decoding the DNA of the Toyota Production System," Harvard Business Review
  • Emiliani, M.L., with Stec, D., Grasso, L. and Stodder, J. (2003), Better Thinking, Better Results: Using the Power of Lean as a Total Business Solution, The CLBM, Kensington, Conn., ISBN 0-9722591-0-4

[edit] See also

[edit] External links

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