TOYOTA

PRODUCTION SYSTEM
LEAN PRODUCTION & JIT SYSTEM

SOURCE: TOYOTA.COM
 The origin of the Toyota Production
System

• A production system that has been fine-tuned over generations

• Roots of the Toyota Production System
• The Toyota Production System (TPS), which is steeped in the
philosophy of "the complete elimination of all waste" imbues all
aspects of production in pursuit of the most efficient methods,
tracing back its roots to Sakichi Toyoda's automatic loom.
• The TPS has evolved through many years of trial and error to
improve efficiency based on the Just-in-Time concept developed by
Kiichiro Toyoda, the founder (and second president) of Toyota Motor
Corporation.

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• Waste can manifest as excess inventory in some cases, extraneous processing steps in
other cases, and defective products in yet other cases. All these "waste" elements
intertwine with each other to create more waste, eventually impacting the
management of the corporation itself.
• The automatic loom invented by Sakichi Toyoda not only automated work which used
to be performed manually but also built the capability to make judgments into the
machine itself. By eliminating both defective products and the associated wasteful
practices, Sakichi succeeded in tremendously improving both productivity and work
efficiency.
• Kiichiro Toyoda, who inherited this philosophy, set out to realize his belief that "the
ideal conditions for making things are created when machines, facilities, and people
work together to add value without generating any waste." He conceived
methodologies and techniques for eliminating waste between operations, between
both lines and processes. The result was the Just-in-Time method.

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• By practicing the philosophies of "Daily Improvements" and "Good
Thinking, Good Products, " the TPS has evolved into a world-
renowned production system.
• Furthermore, all Toyota production divisions are making
improvements to the TPS day and night to ensure its continued
evolution.
• Recently, the "Toyota spirit of making things" is referred to as the
"Toyota Way." It has been adopted not only by companies inside
Japan and within the automotive industry, but in production
activities worldwide, and continues to evolve globally.

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 Sakichi Toyoda
(1867-1930)
• Toyoda Power Loom
equipped with a new
weft-breakage
automatic stopping
device (developed in
1896)
• World's first automatic
loom with a non-stop
shuttle-change motion,
the Type-G Toyoda
Automatic Loom
(developed in 1924)
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 Kiichiro Toyoda
(1894-1952)
• Drawing on his experience of
introducing a flow production
method using a chain conveyor
into the assembly line of a textile
plant (completed in 1927) with a
monthly production capacity of
300 units, Kiichiro Toyoda also
introduced this method into the
body production line at Toyota
Motor Co., Ltd.'s Koromo Plant
(present day Honsha Plant),
completed in 1938.

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 Toyota Standard Sedan Model AA
Type-G Automatic Loom assembly line
announced in 1936

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 Eiji Toyoda (1913-)

• By ensuring thorough
implementation of jidoka and the
Just-in-Time method, Eiji Toyoda
increased workers' productivity by
adding value and realized the
Toyota Production System, which
enabled Toyota to compete head-
on with companies in Europe and
the U.S.

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 Taiichi Ohno
(1912-1990)

• With strong backing from Eiji

Toyoda, Taiichi Ohno helped
establish the Toyota Production
System, and built the foundation
for the Toyota spirit of "making
things" by, for example, creating
the basic framework for the Just-
in-Time method.

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 MURI –OVERBURDEN,
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MURA – UNEVENNESS,
MUDA – NON-VALUE ADDED
 Toyota Production System

• A production system which is steeped in the philosophy of "the

complete elimination of all waste" imbuing all aspects of
production in pursuit of the most efficient methods.
• Toyota Motor Corporation's vehicle production system is a way of
"making things" that is sometimes referred to as a "lean
manufacturing system" or a "Just-in-Time (JIT) system," and has
come to be well known and studied worldwide.
• This production control system has been established based on many
years of continuous improvements, with the objective of "making
the vehicles ordered by customers in the quickest and most efficient
way, in order to deliver the vehicles as quickly as possible."

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 Toyota Production System
• The Toyota Production System (TPS) was established
based on two concepts:
• The first is called “Jidoka" (which can be loosely translated as
"automation with a human touch") which means that when a problem
occurs, the equipment stops immediately, preventing defective
products from being produced;
• The second is the concept of "Just-in-Time," in which each process
produces only what is needed by the next process in a continuous flow.

• Based on the basic philosophies of Jidoka and Just-in-

Time, the TPS can efficiently and quickly produce vehicles
of sound quality, one at a time, that fully satisfy customer
requirements.
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 Jidoka

• Highlighting/visualization of problems
• Quality must be built in during the manufacturing process!
• If equipment malfunction or a defective part is discovered, the
affected machine automatically stops, and operators cease
production and correct the problem.
• As a result, only products satisfying quality standards will be passed
on to the following processes on the production line.

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• Since a machine automatically stops when processing is
completed or when a problem arises and is communicated via
the "andon" (problem display board), operators can
confidently continue performing work at another machine, as
well as easily identify the problem's cause to prevent its
recurrence.
• This means that each operator can be in charge of many
machines, resulting in higher productivity, while continuous
improvements lead to greater processing capacity

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 Just-in-Time

• Productivity improvement
• Making only "what is needed, when it is needed, and in
the amount needed!"
• Producing quality products efficiently through the
complete elimination of waste, inconsistencies, and
unreasonable requirements on the production line.

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 Toyota Production System

In order to deliver a vehicle ordered by a customer as quickly as possible, the vehicle

is efficiently built within the shortest possible period of time by adhering to the
following:
• When a vehicle order is received, a production instruction must be issued to the
beginning of the vehicle production line as soon as possible.
• The assembly line must be stocked with required number of all needed parts so
that any type of ordered vehicle can be assembled.
• The assembly line must replace the parts used by retrieving the same number of
parts from the parts-producing process (the preceding process).
• The preceding process must be stocked with small numbers of all types of parts
and produce only the numbers of parts that were retrieved by an operator from
the next process.

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 References and Sources:

• http://www.toyota-
global.com/company/vision_philosophy/toyota_producti
on_system/illustration_of_the_toyota_production_syste
m.html

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