TOYOTA PRODUCTION SYSTEM CONCEPTS

1. JUST IN TIME Making only "what is needed, when it is needed, and in the amount needed!" JIT is an inventory strategy that a company may chose to implement in order to improve the return on investment of a business by reducing inventory and the costs associated with carrying unsold goods. 2. JIDOKA (Autonomation) Jidoka is a Japanese word that refers to the process of creating an automated production line that also includes a human touch. Machines perform with Autonomation when they are programmed to stop producing in the case of an error. It is then the human who identifies and resolves the problem. 3. KAIZEN (Continuous Improvement) This Japanese term refers to the process of gradual change for the better. Employees are encouraged to provide input and improve the processes that they are over thereby making their jobs more enjoyable and the production line more efficient. 4. KANBAN A visual sign or signal that conveys a set of instructions to either withdraw parts or produce a given product is called a kanban. Kanban is generally recognized as a card that passes between processes, communicating information as to what materials to replenish. 5. ANDON (Signboard) This term refers to a method used in visual control and when translated into English means "Signboard." Visual control is a process that uses visual cues such as graphics to constantly illustrate to workers just how the production process and work environment should flow. 6. POKAYOKE (Mistake Proofing) It is the process of fool-proofing or mistake-proofing a system by identifying the cause of defects or errors and putting a plan in place to prevent such inadvertent errors from occurring again.

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7. MUDA The term muda is often accompanied with a list of seven different wastes or "deadly wastes" that a company looking to implement lean manufacturing techniques is trying to eliminate. (The terms "Muri" and "Mura" refer respectively to the overburden and unevenness that accompanies the carrying of the unnecessary wastes). 8. HEIJUNKA (Flow Production) Heijunka is the elimination of uneveness in workload (mura). This is done by levelling volumes to produce a smooth, continuous and efficient flow. With heijunka, processes are designed to enable products to be switched easily, producing what is needed when it is needed. 9. TAKT TIME Takt is the rate of customer demand. Takt time is the term given to a work-cycle that fulfils each customer's demand.The key is that the workcycle should be synchronised with demand to avoid either underproduction or overproduction. Takt time determines the flow-rate and enables the calculation of how much work can be done. Optimisation of takt time reduces waste and inefficiency by eliminating the risk of time delays or excess production. 10. 5S MODEL Every employee, regardless of position is treated equally. Toyota takes care to nurture a sense of pride and efficiency in the workplace. This is supported by the 5S: SEIRI Tidiness Seiri, which means organization or sort, is used to put things together or to organize them by using specific rules. In other words it means to maintain tidiness at the workplace. SEITON Orderliness Seiton means to straighten or set in order. This step involves a complete focus on efficiency. The intent of this step is to arrange the tools, equipment and parts after a manner that will promote proper work flow.

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SEISO Clean Up Seiso is the sweeping phase or the systematic cleaning of the workplace to keep it neat and tidy. Seiso is a daily activity that should be performed at the end of each shift to ensure everything is cleaned, and restored to its proper place.

SEIKETSU Standardization Even a clean work place with proper selection and proper arrangement will soon become dirty if Seiri, Seiton and Seiso are not continuously repeated. Hence Seiketsu is applied. It means standardizing. Having standardized work practices allows a company to operate in a consistent and standardized manner.

SHITSUKE Discipline Shitsuke means discipline. This last phase is the "glue" that holds the entire process together. Unfortunately people are not perfect. Shitsuke recognizes this and focuses on creating a workplace with good habits.

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