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The Key concept in Toyota Production

System and their own thought― Building original unified man-machine system ―

Iwaki Production System research Ltd.

Toshiaki Yanagida

QuEST APAC Tokyo BPC

4/15/2015

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Introduction

• Welcome to Japan.

• I present about TOYOTA Production System (TPS).

– TPS was production system developed by

TOYOTA and established through long period of

their improvement.

– TPS is famous for the name called “Lean

manufacturing system” and well known in the

world and many people study now.

TOYOTA Production System

Mechanism of TPS・Pull Production

・KANBAN（for Information ）・Automatic stop mechanism

・Small lot production etc.

three basic concepts

(pillars)

The thought

in the undercurrent of TPS

The background・the environment

・their spirit

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What is TOYOTA Production

System (TPS)

• TPS is the total production system what

TOYOTA made by themselves internally

from TOYOTA establishment (1937).

• There are three basic concepts (pillars) in

TPS.

– Just-in-time

– Autonomation: This word is slightly different

– Leveling from usual Automation.

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Just-in-time

• To make and deliver what is needed, just when it is

needed, and just in the amount needed.

• (Originator) Mr.Kiichiro Toyoda‘s Spirit of foundation.

He is a founder of TOYOTA.

• He got an idea from supermarkets in USA.

• Mechanism

– Pull production system

– Information communication by "KANBAN" etc.

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Autonomation＜ Jidouka＞

• Stop and notify abnormalities automatically and

separate man-machine work“. not automation.

• (Originator) Mr. Sakichi Toyoda’s spirit of invention.

He is Mr.Kiichiro‘s father who invented "non-stop shuttle

replacement expression Toyoda automatic loom (type G)".

• "Automation" goes with loss.

• Mechanism

– Automatic stop mechanism against abnormality

– the line stop rule. etc.

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Leveling ＜ Heijunnka＞• Leveling the type and quantity of production over

a fixed period of time.

• (Originator) Mr.Taiichi Ouno who is actual TPS originator

and he thought leveling so strong.

• When the production flow will be much fluctuated,

waste should be much bigger．

• Mechanism

– Small lot production.

– Single setup (changeover). etc.

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The background why TPS was born

(the environment)

• TOYOTA was very late departure company in

comparison with an overseas manufacturer.

• The Japanese market size at that time was

one-50th of the United States.

• Almost none of Infrastructure (technics

related company) was maintained.

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The background why TPS was born

(their spirit)

• They didn't want to follow European and

American style.

• They wanted to manufacture cars by their

original techniques.

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The thought in the undercurrent of TPS

• A person works willingly by oneself.

So we shall utilize these persons.

• The quantity to sell goods is limited.

So we shall work with the limited quantity.

• The quantity involves loss.

So we shall think how to stop loss rather

than quantity at first.

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Way of thinking of quality

improvement in TPS

• It's made in the flow.

• Setting and obeying of standard work (work

procedure, cycle time and the number of holdings).

• Pursuit of root cause ( 5 Why), measure and

level development.

TOYOTA Production System

Mechanism of TPS・Pull Production

・KANBAN（for Information ）・Automatic stop mechanism

・Small lot production etc.

three basic concepts (pillars)・Just-in-time

・Autonomation＜Jidouka＞・Leveling ＜Heijunnka＞

The thought in the undercurrent of TPS

・A person works willingly by oneself.

・The quantity to sell of goods is limited. ・The quantity involves loss.

The background・the environment

・their spirit

Thorough

Exclusion

of

Waste

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Future TPS

• TPS is a production system suitable for multi-

objective production.

• There is accumulation of the technology, know-

how and tools for the past 70 years.

⇒ TPS will grow in future and will spread.

The important thing is that not only

“ the structure of production system ”

but also “ factory culture and their mind ”

is improved together.

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My Expectation

• "Exclusion of waste of the material and

the energy of the person" is also

important thing for the continuation of

the global environment.

• I hope that TPS is useful in the various

parts of the worlds.

Thank you.