Toyota Production System

Toyota Production System

TOYOTA PRODUCTION TOYOTA PRODUCTION SYSTEMSYSTEM

Presented by:Presented by:

RikeshRikesh

RahulRahul


TOYOTA KIRLOSKAR TOYOTA KIRLOSKAR MOTORSMOTORS


VisionVision Contribute to Indian industry and Contribute to Indian industry and

economy through technology economy through technology transfer, human resource transfer, human resource development and vehicles that meet development and vehicles that meet global standards at competitive global standards at competitive price. price.

Contribute to the well-being and Contribute to the well-being and stability of team members. stability of team members.

Contribute to the overall growth for Contribute to the overall growth for our business associates and the our business associates and the automobile industry.automobile industry.


MissionMission Our mission is to design, Our mission is to design,

manufacture and market manufacture and market automobiles in India and overseas automobiles in India and overseas while maintaining the high quality while maintaining the high quality that meets global Toyota quality that meets global Toyota quality standards, to offer superior value standards, to offer superior value and excellent after-sales service. We and excellent after-sales service. We are dedicated to providing the are dedicated to providing the highest possible level of value to highest possible level of value to customers, team members, customers, team members, communities and investors in India. communities and investors in India.


7 Principles of Toyota 7 Principles of Toyota Production SystemProduction System

Reduced setup timeReduced setup time Small-lot productionSmall-lot production Employee Involvement and Employee Involvement and

EmpowermentEmpowerment Quality at the sourceQuality at the source Equipment maintenanceEquipment maintenance Pull ProductionPull Production Supplier involvementSupplier involvement


TOYOTA PRODUCTION TOYOTA PRODUCTION SYSTEMSYSTEM


Production System Production System


JUST-IN-TIMEJUST-IN-TIME

Produced according to what needed, Produced according to what needed, when needed and how much needed. when needed and how much needed.

Strategy to improve return on Strategy to improve return on investment by reducing inventory investment by reducing inventory and associated cost.and associated cost.

The process is driven by The process is driven by KanbanKanban concept. concept.



KANBAN CONCEPTKANBAN CONCEPT

Meaning- Sign, Index Card Meaning- Sign, Index Card It is the most important Japanese concept opted by It is the most important Japanese concept opted by

Toyota.Toyota. Kanban systems combined with unique scheduling Kanban systems combined with unique scheduling

tools, dramatically reduces inventory levels.tools, dramatically reduces inventory levels. Enhances supplier/customer relationships and Enhances supplier/customer relationships and

improves the accuracy of manufacturing schedules.improves the accuracy of manufacturing schedules. A signal is sent to produce and deliver a new A signal is sent to produce and deliver a new

shipment when material is consumed. shipment when material is consumed. These signals are tracked through the refill cycle These signals are tracked through the refill cycle

and bring extraordinary visibility to suppliers and and bring extraordinary visibility to suppliers and buyers.buyers.



Just-in-time --- BenefitsJust-in-time --- Benefits

Set up times are significantly reduced Set up times are significantly reduced in the warehouse.in the warehouse.

The flows of goods from warehouse to The flows of goods from warehouse to shelves are improved. shelves are improved.

Employees who possess multiple skills Employees who possess multiple skills are utilized more efficiently. are utilized more efficiently.

Better consistency of scheduling and Better consistency of scheduling and consistency of employee work hours. consistency of employee work hours.

Increased emphasis on supplier Increased emphasis on supplier relationships relationships


JIDOKAJIDOKA JidokaJidoka (meaning ‘autonomation’)-a term used (meaning ‘autonomation’)-a term used

in Lean manufacturing meaning "automation in Lean manufacturing meaning "automation with a human touch." with a human touch."

It is a quality control process used in the It is a quality control process used in the Toyota Production System which applies the Toyota Production System which applies the following four principles:following four principles:

Detect the abnormality. Detect the abnormality. Stop. Stop. Fix or correct the immediate condition. Fix or correct the immediate condition. Investigate the root cause and install a Investigate the root cause and install a

countermeasure. countermeasure.



JidokaJidoka


Lean ManufacturingLean Manufacturing

Most important concept of Toyota Most important concept of Toyota Production SystemProduction System

A management philosophy focusing A management philosophy focusing on reduction of the seven wastes to on reduction of the seven wastes to improve overall customer value. improve overall customer value.

Toyota Presentation 2002 V2-pg


Key PrinciplesKey Principles Pull processingPull processing products are pulled from the consumer products are pulled from the consumer

end (demand), not pushed from the production end end (demand), not pushed from the production end (Supply) (Supply)

Perfect first-time quality Perfect first-time quality quest for zero defects, quest for zero defects, revealing & solving problems at the source revealing & solving problems at the source

Waste minimization Waste minimization eliminating all activities that do eliminating all activities that do not add value & safety nets, maximize use of scarce not add value & safety nets, maximize use of scarce resources (capital, people and land) resources (capital, people and land)

Continuous improvement Continuous improvement reducing costs, improving reducing costs, improving quality, increasing productivity and information sharing quality, increasing productivity and information sharing

Flexibility Flexibility producing different mixes or greater producing different mixes or greater diversity of products quickly, without sacrificing diversity of products quickly, without sacrificing efficiency at lower volumes of production efficiency at lower volumes of production

Building and maintaining a long term relationship with Building and maintaining a long term relationship with suppliers through collaborative risk sharing, cost suppliers through collaborative risk sharing, cost sharing and information sharing arrangements. sharing and information sharing arrangements.


seven wastes to improve seven wastes to improve overall customer value overall customer value

[ MUDA ][ MUDA ] Transportation Transportation Inventory Inventory Motion Motion Waiting time Waiting time Over-production Over-production Processing Itself Processing Itself Defective Product (Scrap in manufactured Defective Product (Scrap in manufactured

products or any type of business.) products or any type of business.)


Other Toyota Production Other Toyota Production ConceptsConcepts

Heijunka (Production Smoothing)Heijunka (Production Smoothing) Kaizen (Continuous Improvement)Kaizen (Continuous Improvement) Poke-Yoke (to avoid inadvertent Poke-Yoke (to avoid inadvertent

errors)errors) Andon (Signboard)Andon (Signboard) Mura,MuriMura,Muri


Heijunka Heijunka (Production Smoothing)(Production Smoothing)

HeijunkaHeijunka is Japanese term that refers to a is Japanese term that refers to a system of production smoothing designed to system of production smoothing designed to achieve a more even and consistent flow of achieve a more even and consistent flow of work. work.

Heijunka as a concept is closely related to lean Heijunka as a concept is closely related to lean production and just in time manufacturing.production and just in time manufacturing.

A related visual scheduling board known as a A related visual scheduling board known as a heijunka box is often used in achieving heijunka box is often used in achieving heijunka style efficiencies.heijunka style efficiencies.

The use of heijunka as well as broader lean The use of heijunka as well as broader lean production techniques helped Toyota production techniques helped Toyota massively reduce vehicle production times as massively reduce vehicle production times as well as inventory levels during the 1980s.well as inventory levels during the 1980s.


KaizenKaizen Meaning- Continuous ImprovementMeaning- Continuous Improvement Kaizen refers to a workplace 'quality' strategy Kaizen refers to a workplace 'quality' strategy

and related to various quality-control systems.and related to various quality-control systems. It aims to eliminate waste (defined as "activities It aims to eliminate waste (defined as "activities

that add cost but do not add value"). that add cost but do not add value"). Kaizen is a daily activity whose purpose goes Kaizen is a daily activity whose purpose goes

beyond improvement. It is also a process that, beyond improvement. It is also a process that, when done correctly, humanizes the workplace, when done correctly, humanizes the workplace, eliminates overly hard work (both mental and eliminates overly hard work (both mental and physical.physical.

It teaches people how to perform experiments It teaches people how to perform experiments using the scientific method and how to learn to using the scientific method and how to learn to spot and eliminate waste in business processes.spot and eliminate waste in business processes.


Poke-YokePoke-Yoke

Poka-yokePoka-yoke (means "fail-safing" or (means "fail-safing" or "mistake-proofing" — "mistake-proofing" —

avoiding (avoiding (yokeruyokeru) inadvertent errors ) inadvertent errors ((pokapoka)) is a behavior-shaping )) is a behavior-shaping constraint, or a method of constraint, or a method of preventing errors by putting limits preventing errors by putting limits on how an operation can be on how an operation can be performed in order to force the performed in order to force the correct completion of the operation. correct completion of the operation.


Andon (Signboard)Andon (Signboard) AndonAndon is a manufacturing term referring to a signboard is a manufacturing term referring to a signboard

incorporating signal lights, audio alarms, and text or other incorporating signal lights, audio alarms, and text or other displays installed at a workstation to notify management and displays installed at a workstation to notify management and other workers of a quality or process problem.other workers of a quality or process problem.

The alert can be activated manually by a worker, or may be The alert can be activated manually by a worker, or may be activated automatically by the production equipment itself. activated automatically by the production equipment itself. Typically, it will incorporate both a visual indicator and an Typically, it will incorporate both a visual indicator and an audible alarm.audible alarm.

An Andon system is one of the principle elements of the Jidoka An Andon system is one of the principle elements of the Jidoka quality-control method pioneered by Toyota and now part of quality-control method pioneered by Toyota and now part of the Lean methodology. the Lean methodology.

It gives the worker the ability to stop production when a defect It gives the worker the ability to stop production when a defect is found, and immediately call for assistance. is found, and immediately call for assistance.

Work is stopped until a solution has been found out. The alerts Work is stopped until a solution has been found out. The alerts may be logged to a database so that they can be studied as may be logged to a database so that they can be studied as part of a continuous-improvement program.part of a continuous-improvement program.

The system will typically indicate where the alert was The system will typically indicate where the alert was generated, and may also provide a description of the trouble. generated, and may also provide a description of the trouble.

Modern Andon systems can include text, graphics, or audio Modern Andon systems can include text, graphics, or audio elements. elements.

Audio alerts may be done with coded tones, music with Audio alerts may be done with coded tones, music with different tunes corresponding to the various alerts, or pre-different tunes corresponding to the various alerts, or pre-recorded verbal messages.recorded verbal messages.


Mura , Muri Mura , Muri

MuraMura MuraMura is a Japanese term for unevenness. is a Japanese term for unevenness. It is also a key concept in the Toyota Production System It is also a key concept in the Toyota Production System

and is one of the three types of waste (Muda, Mura, Muri) and is one of the three types of waste (Muda, Mura, Muri) it identifies. Waste reduction is an effective way to it identifies. Waste reduction is an effective way to increase profitability.increase profitability.

MuriMuri Muri Muri is a Japanese term for overburden or is a Japanese term for overburden or

unreasonableness.unreasonableness. It is also a key concept in the Toyota Production System It is also a key concept in the Toyota Production System

and is one of the three types of waste (Muda, Mura, Muri) and is one of the three types of waste (Muda, Mura, Muri) it identifies. Waste reduction is an effective way to it identifies. Waste reduction is an effective way to increase profitability.increase profitability.

Muri can be avoided through Muri can be avoided through standardised workstandardised work..


ConclusionConclusion

A Production System that is steeped A Production System that is steeped in the philosophy of the complete in the philosophy of the complete elimination of all wastes and that elimination of all wastes and that

penetrates all aspects of production penetrates all aspects of production with this philosophy in pursuit of the with this philosophy in pursuit of the

most efficient production method.most efficient production method.


THANK YOUTHANK YOU

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Toyota Production System