Toyota Production System

Toyota Production System
Presented by
Kailash Pagare Anurag Mishra Umesh Mishra Rajul Trivedi
XMBA Vile Parle ( Batch No. 14) Professor Amol Roy

Toyoda Family in Auto Industry

The Allied victory and the massive quantities of material behind it (A Bomber an Hour success) caught the attention of Japanese industrialists. Toyoda family were among those Japanese industrialists who were observing American industrial strength and wanted to emulate it by investing in Automotive Industry. Toyoda Automatic Loom Company, under the encouragement of the Japanese government, which needed domestic vehicle production partly due to the worldwide money shortage and partly due to the war with China The Toyota Motor Corporation was founded in September 1933 when Toyoda Automatic Loom created a new division devoted to the production of automobiles under the direction of the founder's son, Kiichiro Toyoda.
Kiichiro Toyoda
The first production model AA in 1936

Toyota Learns From the Ford Motor Company
Toyota found it difficult to emulate Ford Motor Company whose
production system was based on Mass Production System.
Post WWII Japanese economy was in shambles and Toyota could

not afford Mass Production of vehicles due to smaller market size.
Toyotas top bosses begin to design a whole new concept of

Production System which is now also known as Just-in-Time Just-insystem.

At Toyota Motor Company, Taichii Ohno and Shigeo Shingo, are known as the brain Shingo, behind transforming Ford production and other techniques into an approach called Toyota Production System or Lean Production System or Just-in-Time System. Just-inTaichii Ohno
Taichii Ohno was the Production Boss of Toyota Motor Corporation and Shigeo Shigo was industrial engineer and consultant of Toyota Motor Corporation.
Shigeo Shingo
Ford vs. Toyota model of Production System Can be best explained as: Mass Production vs. Lean (JIT) Production

What is Mass Production System Mass production is the name given to the method of producing goods in large quantities at low cost per unit. This system of production is also known as Push System or Just-in-Case System. Just-inTo make it worthwhile, mass production requires mass consumption. With precision equipment, large numbers of identical parts could be produced at low cost and with a small work force.

What is Lean Production System? Lean Production System is the system designed and evolved in Toyota Motor Corporation. It is the modified form of Henry Fords Mass Production System. In some areas its philosophy seem exactly opposite to the fundamental principles of Mass Production System. This system is generally known as JIT system, which in fact is an important pillar of Lean Production System. The slogan of Lean Production is Less is best

Toyota Production System Just-in-Time
Leveled Production Pull System Continuous Flow Processing Takt Time Flexible Work Force 3 Ms 5S
Jidoka (Automation)
Andon-Fixed Position Stop
System
Pokayoke-
Fail Proofing System
Standardized Work
Kaizen (Continuous Improvement)

Just-inJust-in-Time (JIT) System
Just-inJust-in-Time means PRODUCING: a) Only what is needed b) in necessary quantity c) at necessary time

Main Components of JIT

Leveled Production Pull System Continuous Flow Processing Takt Time Flexible Workforce (Shojinka) 3 Ms 5S

Leveled Production means producing various model variations on the same line to cater the customer demand
Conveyer Belt

Pull System (Dont Push) Produce only when your customer demands the product in the required quantity. Run the production according to this demand

Pull System or Kanban System?

Continuous Flow Production In TPS it means arranging work inside each process to flow smoothly from one step to other

Just-in-Case (JIC) Involves the use of buffer or safety stock
Process A
Buffer or Safety Stock
Process B
Process C
Buffer or Safety Stock
Process A
Process B
Process C
Process A
Process B
Process C
Process A
Process B
Process C
Process A
Process B
Process C
Process A
Defect detected at Process B that actually occurred at Process A Process B
Process C

Smooth Flow Processing
Process A
Process B
Process C

Smooth Flow Processing
Process A
Process B
Process C
Defect is detected and countermeasures are taken immediately

Takt Time: Takt is a German word meaning meter. Time: It is the time to finish a given amount of work-doing a single workoperation, making one component, or assembling an entire car.
Total daily operating time Takt time = Total production requirement 480 100
Takt time =
= 4.8 min/ vehicle

Flexible Workforce (Shojinka)
Flexible workforce or shojinka means to alter (decrease or increase) the number of operators within a shop, to equip with demand changes.

MultiMulti-machine Handling
Type of Part
A
Machine (Lathing) Machine (Milling) Machine (Drilling) 1 2 3
D
Unfinished Parts
Machine (Tapping) 4
Finished Products
One person handles one process, four machines

MultiMulti-process Handling
Type of Part
A
Machine (Lathing) Machine (Milling) Machine (Drilling) 1 2 3
Machine (Tapping) 4 One person handles four processes, four machines
3 Ms
MUDA = Non-Value Added NonMURA = Overburden MURI = Unevenness

Muda . Mura . Muri
12 TONS
1 TON
4 ton
Capacity : 4 tons

X 2 = MURI (OVERBURDEN)
6=
MUDA (NON-VALUE ADDED)
MURA (UNEVENNESS)

The most efficient way to deliver 12 tons of good to the destination is:
NO MURI (OVERBURDEN) X 3 = NO MUDA (NO WASTAGE) NO MURA (NO UNEVENNESS)
5S
1. 2. 3. 4. 5. SEIRI SEITON SEISO SEIKETSU SHITSUKE = = = = = SIFTING SORTING SWEEPING SPICK N SPAN SUSTAINANCE

SEIRI = SIFTING
Get rid off unwanted stuff from the workplace
Unwanted
TRASH
SEIRI = SIFTING

SIETON = SORTING
Arranging wanted items in proper order, which means place for every thing and every thing in its place.
Boxes staked well sorted and orderly manner
Disorderly staking
SIETON = SORTING

SIETON = SORTING

SIESO = SWEEPING AND CLEANING
Sweeping and cleaning means surface and other areas free from oil and chemicals that may or may not cause slippage, fire or any other possible hazard.

SEIKETSU = SPICK N SPAN
Spick n span means visible neatness. A nice, clean and tidy workplace Affects directly to the performance and quality of workforce.

SEIKETSU = SPICK N SPAN

SHITSUKE = SUSTAINANCE
Instilling supreme attitude and constantly reminding the workforce about 5 S philosophy through training, competition, encouragement by the top management.

Benefits of JIT
Reduction of direct and direct labor by eliminating non-value added non
activities Reduction of floor space and warehouse space per unit of output Reduction of setup time and schedule delays as the factory becomes a continuous production process. Reduction is waste, rejects, and rework by detecting errors at the source. Reduction of lead time due to small lot sizes, so that downstream work centers provide feedback on quality problems. Better utilization of machines and facilities. Better relations with suppliers. Better integration of and communication between functions such as marketing, purchasing, design, and production. Quality control built into the process.

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Toyota Production System

XMBA Vile Parle ( Batch No. 14) Professor Amol Roy