Toyota Production System
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Stage 2: Accelerating Workingplace Performance @Wengs February 2009, Cikampek 6S & MUDA Waste Eliminations in ACTION Property of Prysmian, Inc. TOYOTA PRODUCTION SYSTEM
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14 Principles of TOYOTA WAYS, Summary of Booklet.On TOYOTA PARADOX @Turning Loss Into Profit.
Transcript of Toyota Production System
Stage 2: Accelerating Workingplace Performance @Wengs
February 2009, Cikampek
6S & MUDA Waste Eliminations in ACTION Property of Prysmian, Inc.
TOYOTA PRODUCTION SYSTEM
Stage 2: Accelerating Workingplace Performance @Wengs
February 2009, Cikampek
6S & MUDA Waste Eliminations in ACTION Property of Prysmian, Inc.
Pabrik KABEL ~ LEAN Manufacturing Excellence???WHY
NOT!?!
Stage 2: Accelerating Workingplace Performance @Wengs
February 2009, Cikampek
6S & MUDA Waste Eliminations in ACTION Property of Prysmian, Inc.
Keinginan KONSUMEN?
• MURAH• BANYAK• BERKUALITAS• MUDAH DITEMUKAN• MUDAH DIDAPAT• JAMINAN GARANSI• JAMINAN SERVISE
Stage 2: Accelerating Workingplace Performance @Wengs
February 2009, Cikampek
6S & MUDA Waste Eliminations in ACTION Property of Prysmian, Inc.
Today Competition…
PricePrice
Profit
Cost
Traditional ThinkingCost + Profit = Price
Price Price
Profit
Cost
Lean ThinkingPrice - Cost = Profit
Untuk mempertahankan kekuatan bisnis:• Memenuhi standard qualitas pelanggan• Penurunan biaya• Harga yang kompetitif• Ketersediaan produk• After Sales Service
How are we make sustainable the business?
Stage 2: Accelerating Workingplace Performance @Wengs
February 2009, Cikampek
6S & MUDA Waste Eliminations in ACTION Property of Prysmian, Inc.
Evolusi continues improvement
Stage 2: Accelerating Workingplace Performance @Wengs
February 2009, Cikampek
6S & MUDA Waste Eliminations in ACTION Property of Prysmian, Inc.
USA ~ JAPAN ~ USA
Visionary Leader : Mr. Taiichi Ohno, 1912 - 1990Guiding principles of TOYOTA PRODUCTION SYSTEM
“We let the flow manage the process, NOT the management manage the processes”
Stage 2: Accelerating Workingplace Performance @Wengs
February 2009, Cikampek
6S & MUDA Waste Eliminations in ACTION Property of Prysmian, Inc.
Apa hubungan TPS & Lean Manufacturing?
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♚1991, DR. James Womack ~ Word Class Manufacturing practices ~ LEAN MANUFACTURING (1996/7)
Stage 2: Accelerating Workingplace Performance @Wengs
February 2009, Cikampek
6S & MUDA Waste Eliminations in ACTION Property of Prysmian, Inc.
General Motor VS TOYOTA
MP09 Inventory PCI ~ 16 Days
Stage 2: Accelerating Workingplace Performance @Wengs
February 2009, Cikampek
6S & MUDA Waste Eliminations in ACTION Property of Prysmian, Inc.
Who is TOYOTA?Toyota Motor CorporationToyota Jidosha Kabushiki-gaisha (トヨタ自動車株式会社)• 1933, Kiichiro Toyoda ~ Type A Engine, Toyoda Automatic
Loom Company• 1936, 1st Model Toyota AA passenger car• 28 August 1937, Toyota Jidosha Kabushiki-gaisha established• Pacific War (WW II) ~ Military Truck production• 1947, starting commercial passenger car production (Model SA)• 1982, starting attach America, NUMMI• 1989, Launching….Lexus in 1989• 1999, NY & London stock exchange• 1st half 2007, 4.72 Mio Vehicles from the target 9.4 Mio; revenue
~ $212Bio & profit $15.1 Bio… Highest achiever in Automotive…Never for GM for 76 years
• 522 subsidiaries & 300k employee world-wide
“Drive your dream… Practice make prefect… Moving forward”
1933, Kiichiro Toyoda
Stage 2: Accelerating Workingplace Performance @Wengs
February 2009, Cikampek
6S & MUDA Waste Eliminations in ACTION Property of Prysmian, Inc.
Mentalitas dalam bekerja
• REWARDSaya akan bekerja jika....
• PUNISHMENTSaya bekerja karena……
• KAIZENSaya bekerja walaupun…..
Stage 2: Accelerating Workingplace Performance @Wengs
February 2009, Cikampek
6S & MUDA Waste Eliminations in ACTION Property of Prysmian, Inc.
1st TOYOTA PARADOXJust in time manufacturingPekerja melakukan Quality Inspection padainput dan output secara mandiriSetiap pekerja memiliki hak untuk ‘STOP PRODUCTION’ pada serius defect danpenyimpanganPekerja merancang system pekerjaannya
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The Second Toyota Paradox: How Delaying Decisions CanMake Better Cars Faster, Sloan Management Review, Spring ‘95,Allen Ward, Jeffrey Liker, John Cristiano, Durward Sobek
Stage 2: Accelerating Workingplace Performance @Wengs
February 2009, Cikampek
6S & MUDA Waste Eliminations in ACTION Property of Prysmian, Inc.
2nd TOYOTA PARADOXSource: A. Ward, J. Liker, J. Cristiano, D. Sobek, The Second Toyota Paradox, Spring 1995, Vol. 36, No. 3
25% Business growth:Pekerja memiliki multi-disiplin dan flexibilitas tinggi, bukandedicated operatorRendah sekali frekuensi melakukan kontak dengan vendor untuk masalah supplyToleran dalam hal improvement dead linePengambilan keputusan yang cepat dan tepatToyota adalah Design engineering
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The real different between Toyota and other vehicle manufacturers is not TOYOTA PRODUCTION SYSTEM.It is because of the TOYOTA Product Development System.
Kosaku Yamada, Chief Engineer Toyota Lexus line
Stage 2: Accelerating Workingplace Performance @Wengs
February 2009, Cikampek
6S & MUDA Waste Eliminations in ACTION Property of Prysmian, Inc.
Visionary Leader : Mr. Taiichi Ohno
Enlightened Philosophy of WorkRespect for WorkersFull utilization of workers’ capabilitiesEntrust workers with greater responsibility & authority
Dramatically New Approach to ProcessBuild only what is neededStop if something goes wrongEliminate anything which does not add value
Stage 2: Accelerating Workingplace Performance @Wengs
February 2009, Cikampek
6S & MUDA Waste Eliminations in ACTION Property of Prysmian, Inc.
Stage 2: Accelerating Workingplace Performance @Wengs
February 2009, Cikampek
6S & MUDA Waste Eliminations in ACTION Property of Prysmian, Inc.
14 Principles of The TOYOTA WaySECTION I: Long Term Philosophy (Principle #1)
People need purpose to find motivation & establish goals
(~ through 5S)
Stage 2: Accelerating Workingplace Performance @Wengs
February 2009, Cikampek
6S & MUDA Waste Eliminations in ACTION Property of Prysmian, Inc.
14 Principles of The TOYOTA WaySECTION II: The Right Process will Produce the Right Result
Principle #2: Continue Process FlowMASS PRODUCTION SYSTEM LEAN PRODUCTION SYSTEM
Stage 2: Accelerating Workingplace Performance @Wengs
February 2009, Cikampek
6S & MUDA Waste Eliminations in ACTION Property of Prysmian, Inc.
Mass Lean / Continuous FlowOperation 1 2 3 Operation 1 2 3
Stage 2: Accelerating Workingplace Performance @Wengs
February 2009, Cikampek
6S & MUDA Waste Eliminations in ACTION Property of Prysmian, Inc.
Waste di tempat kerja?
Stage 2: Accelerating Workingplace Performance @Wengs
February 2009, Cikampek
6S & MUDA Waste Eliminations in ACTION Property of Prysmian, Inc.
8 Wastes at workplace
Wai
ting
MotionDefect
OverProcessing
Competency
Over
Production
Transportatio
nIn
vent
ory
Stage 2: Accelerating Workingplace Performance @Wengs
February 2009, Cikampek
6S & MUDA Waste Eliminations in ACTION Property of Prysmian, Inc.
14 Principles of The TOYOTA WaySECTION II: The Right Process will Produce the Right Result
Principle #3: Pull System“INVENTORY digerakan oleh OUTPUT PRODUCTION”
Stage 2: Accelerating Workingplace Performance @Wengs
February 2009, Cikampek
6S & MUDA Waste Eliminations in ACTION Property of Prysmian, Inc.
14 Principles of The TOYOTA WaySECTION II: The Right Process will Produce the Right Result
Principle #4: Balancing, Level out the workload (Heijunka)
“The slower but consistent tortoise causes less waste and is much more desirable than the speedy hare that races ahead and then stops occasionally to doze. The Toyota Production System can be realized only when all the
workers become tortoises.”- Ohno, 1988 -
Stage 2: Accelerating Workingplace Performance @Wengs
February 2009, Cikampek
6S & MUDA Waste Eliminations in ACTION Property of Prysmian, Inc.
14 Principles of The TOYOTA WaySECTION II: The Right Process will Produce the Right Result
Principle #5: Stop to fix the problem, get right first time (Jidoka)
Jidoka is consist of:1. Poka Yoke ~ Error Proofing2. Automation system3. Andon ~ Visual signal
Stage 2: Accelerating Workingplace Performance @Wengs
February 2009, Cikampek
6S & MUDA Waste Eliminations in ACTION Property of Prysmian, Inc.
14 Principles of The TOYOTA WaySECTION II: The Right Process will Produce the Right Result
Principle #6: Standardize Task & Process
Stage 2: Accelerating Workingplace Performance @Wengs
February 2009, Cikampek
6S & MUDA Waste Eliminations in ACTION Property of Prysmian, Inc.
14 Principles of The TOYOTA WaySECTION II: The Right Process will Produce the Right Result
Principle #7: Visual Control (Andon)
Stage 2: Accelerating Workingplace Performance @Wengs
February 2009, Cikampek
6S & MUDA Waste Eliminations in ACTION Property of Prysmian, Inc.
14 Principles of The TOYOTA WaySECTION II: The Right Process will Produce the Right Result
Principle #8: Technology is pull by Manufacturing (Serving to people & process)
Stage 2: Accelerating Workingplace Performance @Wengs
February 2009, Cikampek
6S & MUDA Waste Eliminations in ACTION Property of Prysmian, Inc.
14 Principles of The TOYOTA WaySECTION III: Add Value to the Organization by Developing people
Principle #9: Educate, Training and Grow Leaders
“If some problem occurs in one-piece-flow manufacturing then the whole production line stops. In this sense it is a very bad system of manufacturing. But when production stops everyone is forced to solve the problem immediately. So team members have to think, and through thinking team members grow and become better team members and people.”
Teruyuki Minoura, former President,
Toyota Motor Manufacturing, North America
Stage 2: Accelerating Workingplace Performance @Wengs
February 2009, Cikampek
6S & MUDA Waste Eliminations in ACTION Property of Prysmian, Inc.
14 Principles of The TOYOTA WaySECTION III: Add Value to the Organization by Developing people
Principle #10: Develop Exceptional People Who Follow Company Philosophy (Motivation & Inspiring people)
Stage 2: Accelerating Workingplace Performance @Wengs
February 2009, Cikampek
6S & MUDA Waste Eliminations in ACTION Property of Prysmian, Inc.
14 Principles of The TOYOTA WaySECTION III: Add Value to the Organization by Developing people
Principle #11: Mutual benefit, Educate & Grow together with Supplier
Stage 2: Accelerating Workingplace Performance @Wengs
February 2009, Cikampek
6S & MUDA Waste Eliminations in ACTION Property of Prysmian, Inc.
14 Principles of The TOYOTA WaySECTION IV: Continues Solving Root Problem Drivers Organization Learning
Principle #12: Go to See (Genchi Genbutsu), Go & Confirm the facts yourself
Stage 2: Accelerating Workingplace Performance @Wengs
February 2009, Cikampek
6S & MUDA Waste Eliminations in ACTION Property of Prysmian, Inc.
14 Principles of The TOYOTA WaySECTION IV: Continues Solving Root Problem Drivers Organization Learning
Principle #13: Make decision based on team & implement rapidly
Stage 2: Accelerating Workingplace Performance @Wengs
February 2009, Cikampek
6S & MUDA Waste Eliminations in ACTION Property of Prysmian, Inc.
14 Principles of The TOYOTA WaySECTION IV: Continues Solving Root Problem Drivers Organization Learning
Principle #14: Learning organization (Hansei) & Continues Improvement (Kaizen)
Stage 2: Accelerating Workingplace Performance @Wengs
February 2009, Cikampek
6S & MUDA Waste Eliminations in ACTION Property of Prysmian, Inc.
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