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Presented byPresented by
± ± KailashKailash PagarePagare
± ± Anurag Anurag MishraMishra ± ± Umesh MishraUmesh Mishra
± ± RajulRajul TrivediTrivedi
XMBAXMBA ± ± Vile Parle ( Batch No. 14)Vile Parle ( Batch No. 14)
Professor Professor ± ± Amol Amol RoyRoy
Toyota Production SystemToyota Production System
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Toyoda Family in Auto IndustryToyoda Family in Auto Industry
The Allied victory and the massive quantities of materialThe Allied victory and the massive quantities of material
behind it (³A Bomber an Hour´ success) caught the attentionbehind it (³A Bomber an Hour´ success) caught the attention
of Japanese industrialists.of Japanese industrialists.
Toyoda family were among those Japanese industrialists whoToyoda family were among those Japanese industrialists who
were observing American industrial strength and wanted towere observing American industrial strength and wanted to
emulate it by investing in Automotive Industry.emulate it by investing in Automotive Industry.
Toyoda Automatic Loom Company, under the encouragementToyoda Automatic Loom Company, under the encouragement
of the Japanese government, which needed domestic vehicleof the Japanese government, which needed domestic vehicle
production partly due to the worldwide money shortage andproduction partly due to the worldwide money shortage andpartly due to the war with Chinapartly due to the war with China
The Toyota Motor Corporation was founded in September The Toyota Motor Corporation was founded in September
1933 when Toyoda Automatic Loom created a new division1933 when Toyoda Automatic Loom created a new division
devoted to the production of automobiles under the directiondevoted to the production of automobiles under the direction
of the founder's son, Kiichiro Toyoda.of the founder's son, Kiichiro Toyoda.
Toyota Production System
Kiichiro Toyoda
The first production model AA in 1936
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Toyota Learns From the Ford Motor CompanyToyota Learns From the Ford Motor Company
Toyota found it difficult to emulate Ford Motor Company whoseToyota found it difficult to emulate Ford Motor Company whose
production system was based on Mass Production System.production system was based on Mass Production System.
Post WWII Japanese economy was in shambles and Toyota couldPost WWII Japanese economy was in shambles and Toyota could
not afford Mass Production of vehicles due to smaller market size.not afford Mass Production of vehicles due to smaller market size.
Toyota¶s top bosses begin to design a whole new concept of Toyota¶s top bosses begin to design a whole new concept of Production System which is now also known as JustProduction System which is now also known as Just--inin--TimeTime
system.system.
Toyota Production System
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At Toyota Motor Company, At Toyota Motor Company, Taichii OhnoTaichii Ohno
andand Shigeo ShingoShigeo Shingo, are known as the brain, are known as the brain
behind transforming Ford productionbehind transforming Ford production andand
other techniques into an approach calledother techniques into an approach called
Toyota Production SystemToyota Production System or Leanor LeanProduction System or Production System or Just Just- -inin- -Time System.Time System.
Taichii Ohno was the Production Boss of Taichii Ohno was the Production Boss of
Toyota Motor Corporation and Shigeo ShigoToyota Motor Corporation and Shigeo Shigowas industrial engineer and consultant of was industrial engineer and consultant of
Toyota Motor Corporation.Toyota Motor Corporation.
Toyota Production System
Taichii Ohno
Shigeo Shingo
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Ford vs. Toyota model of Production SystemFord vs. Toyota model of Production System
Can be best explained as:Can be best explained as:
Mass Production vs. Lean (JIT) ProductionMass Production vs. Lean (JIT) Production
Toyota Production System
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What is Mass Production SystemWhat is Mass Production System
Mass productionMass production is the name given to theis the name given to themethod of producing goods in largemethod of producing goods in largequantities at low cost per unit.quantities at low cost per unit.
This system of production is also knownThis system of production is also knownas Push System or Justas Push System or Just--inin--Case System.Case System.
To make it worthwhile, mass productionTo make it worthwhile, mass productionrequires mass consumption.requires mass consumption.
With precision equipment, large numbersWith precision equipment, large numbersof identical parts could be produced at lowof identical parts could be produced at lowcost and with a small work force.cost and with a small work force.
Toyota Production System
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What is Lean Production System?What is Lean Production System?
Lean Production System is the systemLean Production System is the system
designed and evolved in Toyota Motor designed and evolved in Toyota Motor
Corporation.Corporation.
It is the modified form of Henry FordsIt is the modified form of Henry Fords
Mass Production System. In someMass Production System. In some
areas its philosophy seem exactlyareas its philosophy seem exactly
opposite to the fundamental principlesopposite to the fundamental principles
of Mass Production System.of Mass Production System.This system is generally known as JITThis system is generally known as JIT
system, which in fact is an importantsystem, which in fact is an important
pillar of Lean Production System.pillar of Lean Production System.
The slogan of Lean Production is ³LessThe slogan of Lean Production is ³Less
is best´is best´
Toyota Production System
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Toyota Production System
Toyota Production System
Just-in-Time
Leveled Production
Pull System
Continuous Flow
Processing
Takt Time
Flexible Work Force 3 Ms
5 S
Standardized Work Kaizen (Continuous Improvement)
Jidoka (Automation)
Andon-Fixed Position Stop
System
Pokayoke- Fail Proofing
System
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JustJust--inin--Time (JIT) SystemTime (JIT) System
JustJust--inin--Time means PRODUCING:Time means PRODUCING:
a) Only what is neededa) Only what is needed
b) in necessary quantityb) in necessary quantity
c) at necessary timec) at necessary time
Toyota Production System
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Main Components of JITMain Components of JIT
Leveled ProductionLeveled Production
Pull SystemPull System
Continuous Flow ProcessingContinuous Flow Processing
Takt TimeTakt Time
Flexible Workforce (Shojinka)Flexible Workforce (Shojinka)
3 Ms3 Ms
5 S5 S
Toyota Production System
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Leveled Production means producingLeveled Production means producing
various model variations on the same linevarious model variations on the same line
to cater the customer demandto cater the customer demand
Toyota Production System
Conveyer Belt
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Pull System (Don¶t Push)Pull System (Don¶t Push)
Produce only when your customer Produce only when your customer
demands the product in the requireddemands the product in the requiredquantity.quantity.
Run the production according to thisRun the production according to this
demanddemand
Toyota Production System
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Pull System or Kanban System?Pull System or Kanban System?
Toyota Production System
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Toyota Production System
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Continuous Flow ProductionContinuous Flow Production
In TPS it means arranging work insideIn TPS it means arranging work insideeach process to flow smoothly from oneeach process to flow smoothly from one
step to other step to other
Toyota Production System
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Toyota Production System
Process A
Process C
Process B
Just-in-Case (JIC) Involves the use of buffer or safety stock
Buffer
or
Safety Stock
Buffer
or
Safety Stock
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Toyota Production System
Process A
Process C
Process B
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Toyota Production System
Process A
Process C
Process B
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Toyota Production System
Process A
Process C
Process B
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Toyota Production System
Process A
Process C
Process B
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Toyota Production System
Process A
Process C
Process B
Defect detected at
Process B that
actually
occurred at
Process A
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Toyota Production System
Process A Process B Process C
Smooth Flow Processing
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Toyota Production System
Process A Process B Process C
Smooth Flow Processing
Defect is detected and
countermeasures
are taken immediately
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Takt TimeTakt Time: Takt is a German word meaning ³meter´.: Takt is a German word meaning ³meter´.
It is the time to finish a given amount of workIt is the time to finish a given amount of work--doing a singledoing a single
operation, making one component, or assembling an entire car.operation, making one component, or assembling an entire car.
Toyota Production System
Takt time =Total daily operating time
Total production requirement
Takt time =
480
100= 4.8 min/ vehicle
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Flexible Workforce (Shojinka)Flexible Workforce (Shojinka)
Flexible workforce or shojinka means toFlexible workforce or shojinka means to
alter (decrease or increase) the number of alter (decrease or increase) the number of
operators within a shop, to equip withoperators within a shop, to equip withdemand changes.demand changes.
Toyota Production System
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MultiMulti--machine Handlingmachine Handling
Toyota Production System
Type of Part
A B C D
Machine (Lathing) 1
Machine (Milling) 2
Machine (Drilling) 3
Machine (Tapping) 4
One person handles one process, four machines
Unfinished Parts
Finished Products
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MultiMulti--process Handlingprocess Handling
Toyota Production System
Type of Part
A B C D
Machine (Lathing) 1
Machine (Milling) 2
Machine (Drilling) 3
Machine (Tapping) 4
One person handles four processes, four machines
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33 MM¶s¶s
MMUDA = NonUDA = Non--Value AddedValue Added
MMURA = OverburdenURA = Overburden
MMURI = UnevennessURI = Unevenness
Toyota Production System
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Toyota Production System
1 TON
4 ton
Capacity : 4 tons
Muda . Mura . Muri
12 TONS
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Toyota Production System
X
X
2 = MURI (OVERBURDEN)
6 = MUDA (NON-VALUE ADDED)
= MURA (UNEVENNESS)
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The most efficient way to deliver 12 tons of good to the destination is:The most efficient way to deliver 12 tons of good to the destination is:
Toyota Production System
X 3 =
NO MURI (OVERBURDEN)
NO MUDA (NO WASTAGE)
NO MURA (NO UNEVENNESS)
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Toyota Production System
5S1. SEIRI = SIFTING
2. SEITON = SORTING
3. SEISO = SWEEPING
4. SEIKETSU = SPICK µN¶ SPAN5. SHITSUKE = SUSTAINANCE
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SEIRI = SIFTINGSEIRI = SIFTING
Get rid off unwanted stuff from the workplaceGet rid off unwanted stuff from the workplace
Toyota Production System
TRASH
Unwanted
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SEIRI = SIFTINGSEIRI = SIFTING
Toyota Production System
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SIETON = SORTINGSIETON = SORTING
Arranging wanted items in proper order, which means place for Arranging wanted items in proper order, which means place for
every thing and every thing in its place.every thing and every thing in its place.
Toyota Production System
Boxes staked well
sorted and orderly
manner
Disorderly staking
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SIETON = SORTINGSIETON = SORTING
Toyota Production System
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SIETON = SORTINGSIETON = SORTING
Toyota Production System
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SIESO = SWEEPING AND CLEANINGSIESO = SWEEPING AND CLEANING
Sweeping and cleaning means surface and other areas free from oilSweeping and cleaning means surface and other areas free from oil
and chemicals that may or may not cause slippage, fire or anyand chemicals that may or may not cause slippage, fire or any
other possible hazard.other possible hazard.
Toyota Production System
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SEIKETSU = SPICK µN¶ SPANSEIKETSU = SPICK µN¶ SPAN
Toyota Production System
Spick µn¶ span means visible neatness. A nice, clean and tidy workplace
Affects directly to the performance and quality of workforce.
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SEIKETSU = SPICK µN¶ SPANSEIKETSU = SPICK µN¶ SPAN
Toyota Production System
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SHITSUKE = SUSTAINANCESHITSUKE = SUSTAINANCE
Instilling supreme attitude and constantly reminding theInstilling supreme attitude and constantly reminding the
workforce about 5 S philosophy through training, competition,workforce about 5 S philosophy through training, competition,
encouragement by the top management.encouragement by the top management.
Toyota Production System
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Benefits of JITBenefits of JIT
Reduction of direct and direct labor by eliminating nonReduction of direct and direct labor by eliminating non--value addedvalue addedactivitiesactivities
Reduction of floor space and warehouse space per unit of outputReduction of floor space and warehouse space per unit of output
Reduction of setup time and schedule delays as the factoryReduction of setup time and schedule delays as the factorybecomes a continuous production process.becomes a continuous production process.
Reduction is waste, rejects, and rework by detecting errors at theReduction is waste, rejects, and rework by detecting errors at thesource.source.
Reduction of lead time due to small lot sizes, so that downstreamReduction of lead time due to small lot sizes, so that downstream
work centers provide feedback on quality problems.work centers provide feedback on quality problems. Better utilization of machines and facilities.Better utilization of machines and facilities.
Better relations with suppliers.Better relations with suppliers.
Better integration of and communication between functions such asBetter integration of and communication between functions such asmarketing, purchasing, design, and production.marketing, purchasing, design, and production.
Quality control built into the process.Quality control built into the process.
Toyota Production System
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Toyota Production System