A Quick Look At The Toyota Production System - TPS

A Quick Look At The Toyota Production System - TPS

Toyota is presently the worlds main automobile producer, producing consistent higher performing and less expensive cars than any of the foremost American brands. How do they obtain this remarkable feat? Is there some secret sauce to their system?

Properly, yes, there may be some secret sauce. But it is not so secret - it's really fairly effectively documented. It is called the Toyota Production System, and I might like to clarify a little bit about it today.

TPS is a completely integrated socio-technical system comprising of it's management principles, firm philosophy, and manufacturing practices. Originally known as "just in time" (or JIT), it attracts upon the work of the founders of Toyota, his son, and an engineer - which in flip drew their inspiration from Henry Ford. The Toyota employees got here to America to look at the Ford manufacturing strategies, however had been decidedly unimpressed with the whole 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 terms muda, mura, and muri. The process should deliver the required results smoothly - without inconsistencies; while being as flexible as essential with out overburdening the workers, which might end in waste.

What's waste as addressed by TPS? 7 sorts have been recognized:

Motion (of man or machine)
Waiting (of man or machine)
Processing itself
Inventory (raw supplies)
Correction (rework and scrap)

The physical price of correcting defective merchandise or disposing of them is obvious, however the rest might have explaining. Motion waste may discuss with extra actions required on the part of the assembly line worker who must physically carry gadgets from one machine to a different - which may very well be reduced by connecting the machines. Ready waste refers back to the time when one machine lies unused, because it is still "waiting" for one more course of within the production line to complete - you may't put the lights on the automotive till the paint has dried, for instance. Wastage of raw supplies can happen because the design of the machine is such that creating lean culture it requires 1m squared of metal to chop a single 50cm squared form - with correct designing, these may mixed into 1 bigger sheet with much less waste cut.