A Quick Look At The Toyota Production System - TPSToyota is currently the worlds leading automobile manufacturer, producing consistent higher performing and more cost effective cars than any of the major American brands. How do they achieve this remarkable feat? Is there some secret sauce to their formula?
Well, sure, there may be some secret sauce. However it is not so secret - it's actually pretty nicely documented. It's called the Toyota Production System, and I'd like to clarify somewhat about it today.
TPS is a fully built-in socio-technical system comprising of it's management ideas, company philosophy, and manufacturing practices. Initially referred to as "just in time" (or JIT), it attracts upon the work of the founders of toyota production system (tps), his son, and an engineer - which in turn drew their inspiration from Henry Ford. The Toyota workers came to America to observe the Ford manufacturing methods, but have been decidedly unimpressed with the entire operation. From that experience, and observations of an automatic drink resupply system in the supermarket, they fashioned the ideas of TPS.
The target of TPS is to reduce waste, inconsistency, and overburden. These are embodies within the Japanese phrases muda, mura, and muri. The process should deliver the required results smoothly - with out inconsistencies; while being as flexible as mandatory with out overburdening the workers, which might lead to waste.
What is waste as addressed by TPS? 7 varieties have been recognized:
Movement (of man or machine)
Ready (of man or machine)
Inventory (uncooked supplies)
Correction (rework and scrap)
The physical price of correcting defective merchandise or disposing of them is apparent, however the remainder might have explaining. Motion waste might seek advice from additional actions required on the a part of the assembly line employee who should physically carry items from one machine to another - which might be reduced by connecting the machines. Ready waste refers back to the time when one machine lies unused, because it's nonetheless "waiting" for an additional course of in the manufacturing line to complete - you may't put the lights on the car till the paint has dried, for instance. Wastage of uncooked supplies can occur because the design of the machine is such that it requires 1m squared of metal to cut a single 50cm squared shape - with proper designing, these could combined into 1 bigger sheet with less waste cut. Website URL: