SKANDA SOLUTIONS
READYMADE MBA PROJECTS IN PRODUCTION MANAGEMENT
TOYOTA PRODUCTION SYSTEM (TPS)
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.“
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.
GOALS OF TOYOTA PRODUCTION SYSTEM (TPS)
- Provide world class quality and service to the customer.
- Develop each employee’s potential, based on mutual respect, trust and cooperation.
- Reduce cost through the elimination of waste and maximize profit
- Develop flexible production standards based on market demand.
Just In Time (JIT).
The JIT concept aims to produce and deliver the right
parts, in the right amount, at the right time using the minimum necessary
resources. This system reduces inventory and strives to prevent both early
and over production. Producing in a JIT fashion exposes problems quickly. With
less inventory in a system, the “rocks” or "problems" in production that are disrupting flow are quickly exposed. Most companies shy away problems and use inventory to hide
these problems and avoid potential disruptions. In Toyota, however the opposite
logic is applied. By reducing inventory you expose the real problems in a
production process quickly and focus on the need for improvement. This notion of
surfacing problems and abnormalities is a critical concept in TPS. (Toyota Production System). Of course
unless you can solve the problem that you expose, there is a danger to this
approach.
There are several important components to TPS: takt time,
flow production, pulls via kanban, and leveling (heijunka).
JIDOKA (Build in quality)
Jidoka is the second pillar of the system. There are two
parts to Jidoka –
- Building in quality at the process and
- Enabling separation of man from machine in work environments.
Jidoka is a Japanese word that ordinarily means automatic or
automation. However Toyota puts a specific twist on this word by adding what
is known as a “radical” in depicting kanji characters. The radical added to the
left of one of the kanji characters in Jidoka means “human”. In other words TPS
aspires for processes that are capable of making intelligent decisions and
shutting down automatically at the first sign of an abnormal condition such as
a defect or other problem. The goal is not to run continuously but in other
words to stop.
FOCUS AREA OF TPS
- Eliminating Waste
- Quality
- Cost
- Productivity
- Safety and Morale.
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