Presented By-MOHD.ARISH

INTRODUCTION

The Toyota Production System (TPS) is an integrated socio-

technical system, developed by Toyota, that comprises its

management philosophy and practices.

The TPS organizes manufacturing and logistics for the

automobile manufacturer, including interaction with suppliers

and customers.

The system is a major precursor of the more generic "Lean

manufacturing.

CONTD…………

1897:- Sakichi Toyoda diversified his business.

1926:- He formed Toyoda Automatic Loom Works (TALW) to

manufacturing Loom workers

1933:- Established an Automobile department within TALW.

1935:- First Passenger car prototype was developed.

1936:- Sakichi sold the patent rights of his Automatic loom to a UK

based Company.

1947:- The passenger cars production began.

1950-1955:- Foundation of Kanban System.

1957:- Eijji Renamed Toyota as “The Toyota Company”

1968:- Toyota’s first export to the USA.

1970s:- Major boost in the Japan due to oil crises.

1980s:- Toyota brought TPS in the USA with a Joint Venture to The GM.

1983:- Company’s name changed to Toyota motor Corporation.

1988:- Toyota Opened its New plant in Georgetown.

1999-2000:- Toyota listed on NYSE & LSE and become one of the top

manufactures of cars in the world.

TOYATA PRODUCTION SYSTEM

Tahchi Ohno’s ( Assembly manager)

Simplify the concept and develop them into formal system.

Experimented various ways of setting of the equipment.

Trained the engineer’s about how to use and implement the system.

Efficient use of available resources by reducing wastes and lowering costs.

FEATURES OF TPS

TPS

TECHNICAL RELATED

JIT

KANBAN

PEOPLE RELATED

WORKERS

SUPPLIERS

JUST IN TIME (JIT)

It is foundation of TPS.

Right use of time and amount

JIT become important because of scarce flat, industrial, land.

Advantage of making its own component

KANBAN

KANBAN

WITHDRAWL CONVEYANCE

PRODUCTION

Kanban is used to facilitate the movement of inventory between

different process on the production line.

Withdrawal Kanban is carried when going from one process to the

preceding process.

Production Kanban is used to order production of the portion

withdrawn by the subsequent process.

KAIZAN

It is small incremental changes made for improving productivity and

minimizing waste.

Improvement of process flow to reduce wastage.

The changes are generally small and incremental.

Observation is best way to spot problems.

Understand problem.

BENEFITS OF KAIZAN

Reduces waste

Improvement

Result in higher employee

HUMAN ELEMENT

The main consideration in TPS:-

Elimination of wasteful movements by workers.

Consideration of workers safety.

Self display of workers capabilities by entrusting them with responsibility and authority.

TPS Emphasized on flexibility and teamwork.

Benefits

Less time for implementation

Achieve a high degree of flexibility

Strong relationship

with suppliers

Making best use of its

resources got greater

productivity

PROMOTION

Toyota set up the TSCC ,headquartered in Kentucky

Toyota did not charge any fee for its services, and only the

consultants expenses had to be reimbursed by the client.

SYSTEM OF THE FUTURE

Standard global production system of the future.

Successful companies from US & Europe implementing TPS.

General Mills, a major US food company.

Gorton’s fish processing unit- in reducing inventory.

Hickory Chair kept prices steady for 3 years by

adopting TPS & FUJITSU company recovering from

losses by implementing TPS in streamline operations.