Toyota Production System
From Free net encyclopedia
The Toyota Production System (TPS) (トヨタ生産方式) is the framework and philosophy organizing the manufacturing facilities at Toyota and the interaction of these facilities with the suppliers and customers. It was largely created by three men: the founder of Toyota, Sakichi Toyoda, his son Kiichiro Toyoda, and engineer Taiichi Ohno. The main goal of the TPS is to eliminate waste (無駄, Muda). There are 7 kinds of waste targeted in the TPS.
- Defects
- Overproduction
- Transportation
- Waiting
- Inventory
- Motion
- Processing itself
Toyota was able to greatly reduce cost and inventory using the TPS, enabling it to become one of the ten largest companies in the world. The TPS is a classic example of the Kaizen approach to productivity improvement. Due to this stellar success of the production philosophy many of these methods have been copied by other manufacturing companies. TPS is known more generically as Lean manufacturing.
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Commonly used terminology in TPS:
- Just In Time (ジャストインタイム) (JIT)
- Kanban (看板, also かんばん) (engl.: Sign, Index Card)
- Muda (無駄, also ムダ) (engl.: Waste)
- Heijunka (平準化) (engl.: Production Smoothing)
- Andon (アンドン) (engl.: Signboard)
- Poka-yoke (ポカヨケ) (engl.: fail-safing - to avoid (yokeru) inadvertent errors (poka))
- Jidoka (自働化) (engl.: Autonomation - automation with human intelligence)
- Kaizen (改善) (engl.: Continuous Improvement)
References
- Taiichi Ohno (1995), Toyota Production System: Beyond Large-scale Production, Productivity Press Inc., ISBN 0915299143.
- Yasuhiro Monden (1998), Toyota Production System, An Integrated Approach to Just-In-Time, Third edition, Spring, ISBN 041283930X.
- Jeffrey Liker (2003), The Toyota Way: 14 Management Principles from the World's Greatest Manufacturer, First edition, McGraw-Hill, ISBN 0071392319.
- Womack, James P. and Jones, Daniel T. (2003), Lean Thinking: Banish Waste and Create Wealth in Your Corporation, Revised and Updated, HarperBusiness, ISBN 0743249275.
- Womack, James P., Jones, Daniel T., and Roos, Daniel (1991), The Machine That Changed the World: The Story of Lean Production, HarperBusiness, 2003, ISBN 0060974176.
- Shigeo Shingo (1989) A Study of the Toyota Production System from an Industrial Engineering Viewpoint (Produce What Is Needed, When It's Needed), Productivity Press, ISBN 0915299178. (This refers to the English version; the Japanese version was published in 1981, but the ISBN is unknown)
- Spear, Steven, and Bowen, H. Kent (September 1999), "Decoding the DNA of the Toyota Production System," Harvard Business Review
- Emiliani, M.L., with Stec, D., Grasso, L. and Stodder, J. (2003), Better Thinking, Better Results: Using the Power of Lean as a Total Business Solution, The CLBM, Kensington, Conn., ISBN 0972259104