Taiichi Ohnos contributions

Presentation by: Cody Johnson BYU Student

Taiichi Ohno Contribution Outline

Who is Taiichi Ohno?

Key terms and meanings
What is the Toyota Production System
View the basics of the TPS
Where do many of the ideas stem from
Review the Seven Wastes
Asking why 5 times
Stagnation = waste

Outline Continued:
Key component to TPS JIT What is it?
Brainstorming Activitiy Takt Time
Key Componenet to TPS explained Kanban
System
Summary
Sources/Readings List

Taiichi Ohno
Who is Taiichi Ohno?
Born in China but known as a Japanese Businessman

What is he known for?

Being the father of the Toyota Production System (TPS)

Ohno drove development and practical application of the

TPS
Believed in teaching leadership by example and
empowering employees
Quote from Ohno: Costs do not exist to be calculated, they exist to be reduced.

Key terms and meanings

Just-in-time: getting what is needed at the time it is needed in the quantity needed (JIT)
Kanban: Simple, clear, fast means of communication
Autonomation: separation of machine and man
Muda: Waste, anything that is non-value added
Poka-Yoke: A failsafe, instruments in place to avoid mistakes
Heijunka: The discipline of leveling customer demand (Quantity and Variety)
Kaizen: continuous improvement
Takt Time: referred to as the time it takes to assemble products in each stage of the
manufacturing process

Jidoka: automation with a human touch

What is the Toyota Production System?

*Two main pillars*

Continuous Improvement - often referred to

as Kaizen
Respect for People

The Basics of TPS

Heijunka Preexisting condition Keep it level

JIT
a. Pull System
b. Continuous Flow
c. Takt Time

JIDOKA
a. Stop and Fix
b. Separate Human & Machine

Create flow of parts and seek people contributing to the company

Where did Toyota get their ideas for the TPS?

Experiencing major material shortages

because of the war

Henry Ford and his book

Ford Model T - 1908

The Seven Wastes of the TPS MUDA

Overproduction
Waiting
Transporting
Too much machining (Over-processing)

You must
first understand the nature of waste before it can be recognized
Inventories

Asking Why 5 times

Critical component of problem solving
Goal: find the root cause of the problem
The direct root cause should point to a
process after asking the 5 whys

What is stagnation and how do

we eliminate waste?
Products are always changing
-How can we add value
We must have a continuous flow

*Stagnation is considered waste, no matter what

form it is in.

Keep the flow with Takt Time

Just-in-time (JIT)

Developed to eliminate inventory

Produce What is needed
At the time it is needed
In the Quantity needed

ACCOMPLISHED

Pull Systems (Kanban signals)

Keeping Takt Time (pace of sales)

Brainstorming Activity Takt Time

Formula for Takt Time =
Time Available = Amount of scheduled work time per shift

Time Available
Customer Demand

EXAMPLE:
8.00 hrs. per shift minus .80 hrs of break and lunch
= 7.2 hours of work time

We need to convert minutes to seconds:

7.2 hours X 60 min.= 432 min.

432min.X 60 sec.= 25,920 sec.

Brainstorming Activity Takt Time

Now that we have Time Available, we need to compute
customer demand.
Customer Demand (Parts Required) = Demand per shift
Weekly Demand
# of Shifts per week = Demand per shift
EXAMPLE:
27,000 demand per week

10 shifts per week

= 2,700 units per shift

Brainstorming Activity Takt Time

EXAMPLE:
Takt time = Time Available
Parts Required (Customer Demand)
= 25,920 seconds per shift
2,700 units per shift
= 9.6 seconds per unit

*Every 9.6 seconds one unit should be produced*

What if we are
running faster than
Takt Time?
Inventory increases
Lead times increase
Demand on
suppliers increase
Cost increase

What if we are running slower than

Takt Time?

Overtime needed to meet demand

Product increases in cost

Shipping costs will increase

Customer dissatisfaction

Missed shipments

Kanban system
A pull system What is a pull system?
Pull means that nobody upstream will produce goods or
services until the customer downstream asks for it
VS.

Push means produce even if there is no demand

Supplier

How does a Kanban Pull

system work?
Inventory
Shop Stock

*This side you are seeing the flow of

material
Final Assembly

Store/Shipping Dock

*This side you are seeing the flow of

information. A signal is sent to notify that

Customer

Summary

Much to learn about the TPS concepts

Terms are simple and straightforward
Identify the seven wastes
Asking why 5 times can make a difference
JIT and Kanban if implemented correctly, can be
extremely beneficial for your organization
Always be looking for waste WASTE = $$

Readings list: Sources

Toyota Production System written by Taiichi
Ohno.
The Toyota Way written by Jeffrey Liker
I worked at US Synthetic in Orem, Utah and took
a Lean certification class. They base much of their
manufacturing off of the TPS. I received a lot of
information from my research from the hand book
for this certification class through US Synthetic