Toyota Production System
##Toyota Production System##
Toyota Production System (TPS) is a systematic method which focuses on eliminating waste, or Muda, from the manufacturing system. Later a more generic term named lean manufacturing is derived from TPS.
The philosophy, which is employed by each employee in their works and interactions, was first introduced by Sakichi Toyoda and later improved by Taiichi Ohno.
TPS is based on 5 core values which are
- Genchi Genbutsu
- Kaizen
- Challenge
- Teamwork
- Respect
TPS is comprised of two pillars, just-in-time and jidoka, and often is illustrated with the “house” example:
Kanban cards which are employed to replenish the parts when stocks become low and Takt times which records the time it takes to produce components are main resources for Just in Time pillar.
Jidoka, which means making abnormalities visible, is the idea which enables each team member to stop process of production when a possible problem occurs. Team members are always encouraged to practice Genchi Genbutsu which means finding the root of the problem. The purpose of it is to provide reliable products.
Alongside of these two pillars, Kaizen is one of the main foundations of this philosophy. With the meaning of continuous improvement, Kaizen gives the soul of the philosophy.
As a main aspect, teamwork is at a very high importance at TPS. Each member is asked to actively participate in meetings, give their opinions and make suggestions. It requires commitment from everyone.
With strong foundations and blocks, this philosophy has led Toyota from a small company to the world's largest automaker. It focuses on not only efficiency problems but also human aspect of manufacturing process, tries to create a well structure working environment and therefore improve productivity and supply customers better products and service.
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