Toyota Production

Just-in-Time Philosophy of complete elimination of waste
Just-in-Time
"Just-in-Time" means making "only what is needed, when it is needed, and in the amount
needed." For example, to efficiently produce a large number of automobiles, which can
consist of around 30,000 parts, it is necessary to create a detailed production plan that
includes parts procurement. Supplying "what is needed, when it is needed, and in the
amount needed" according to this production plan can eliminate waste, inconsistencies, and
unreasonable requirements, resulting in improved productivity.
Kanban System
In the TPS (Toyota Production System), a unique production control method called the
"kanban system" plays an integral role. The kanban system has also been called the
"Supermarket method" because the idea behind it was borrowed from supermarkets. Such
mass merchandizing stores use product control cards upon which product-related
information, such as a product's name, code and storage location, are entered. Because
Toyota employed kanban signs for use in their production processes, the method came to be
called the "kanban system." At Toyota, when a process refers to a preceding process to
retrieve parts, it uses a kanban to communicate which parts have been used.
Evolution of the kanban through daily improvements
Through continuous technological improvements, the kanban system has evolved into the "ekanban," which is managed using IT methodologies and has increased productivity even
further.
- Why use a supermarket concept?

A supermarket stocks the items needed by its customers when they are needed in the
quantity needed, and has all of these items available for sale at any given time.
Taiichi Ohno (a former Toyota vice president), who promoted the idea of Just-in-Time,
applied this concept, equating the supermarket and the customer with the preceding
process and the next process, respectively. By having the next process (the customer) go to
the preceding process (the supermarket) to retrieve the necessary parts when they are
needed and in the amount needed, it was possible to improve upon the existing inefficient
production system. No longer were the preceding processes making excess parts and
delivering them to the next process.
Two kinds of kanban (the production instruction kanban and the parts retrieval kanban) are used for
managing parts.
Jidoka Manufacturing high-quality products

Automation with a human touch
The term jidoka used in the TPS (Toyota Production System) can be defined as "automation
with a human touch." The word jidoka traces its roots to the invention of the automatic
loom by Sakichi Toyoda, Founder of the Toyota Group. The automatic loom is a machine that
spins thread for cloth and weaves textiles automatically.
Before automated devices were commonplace, back-strap looms, ground looms, and highwarp looms were used to manually weave cloth. In 1896, Sakichi Toyoda invented Japan's
first self-powered loom called the "Toyoda Power Loom." Subsequently, he incorporated
numerous revolutionary inventions into his looms, including the weft-breakage automatic
stopping device (which automatically stopped the loom when a thread breakage was
detected), the warp supply device and the automatic shuttle changer. Then, in 1924, Sakichi
invented the world's first automatic loom, called the "Type-G Toyoda Automatic Loom (with
non-stop shuttle-change motion)" which could change shuttles without stopping operation.
The Toyota term "jido" is applied to a machine with a built-in device for making judgments,
whereas the regular Japanese term "jido" (automation) is simply applied to a machine that
moves on its own. Jidoka refers to "automation with a human touch," as opposed to a
machine that simply moves under the monitoring and supervision of an operator.
Since the loom stopped when a problem arose, no defective products were produced. This
meant that a single operator could be put in charge of numerous looms, resulting in a
tremendous improvement in productivity.
Type-G Toyoda Automatic Loom, the origin of jidoka
The Type-G Toyoda Automatic Loom, the world's first automatic loom with a non-stop shuttlechange motion, was invented by Sakichi Toyoda in 1924. This loom automatically stopped
when it detected a problem such as thread breakage.
Concept of jidoka
Jidoka and Visual Control

Since equipment stops when a problem arises, a single operator can visually monitor and
efficiently control many machines. As an important tool for this "visual control" or "problem
visualization," Toyota plants use a problem display board system called "andon" that allows
operators to identify problems in the production line with only a glance.
Visual Control using Andon
An operator communicating an abnormality
An andon problem display board that communicates abnormalities
The origin of the Toyota Production System

A production system that has been fine-tuned over generations
Roots of the Toyota Production System
The Toyota Production System (TPS), which is steeped in the philosophy of "the complete
elimination of all waste" imbues all aspects of production in pursuit of the most efficient
methods, tracing back its roots to Sakichi Toyoda's automatic loom. The TPS has evolved
through many years of trial and error to improve efficiency based on the Just-in-Time
concept developed by Kiichiro Toyoda, the founder (and second president) of Toyota Motor
Corporation.
Waste can manifest as excess inventory in some cases, extraneous processing steps in other
cases, and defective products in yet other cases. All these "waste" elements intertwine with
each other to create more waste, eventually impacting the management of the corporation
itself.
The automatic loom invented by Sakichi Toyoda not only automated work which used to be
performed manually but also built the capability to make judgments into the machine itself.
By eliminating both defective products and the associated wasteful practices, Sakichi
succeeded in tremendously improving both productivity and work efficiency.
Kiichiro Toyoda, who inherited this philosophy, set out to realize his belief that "the ideal
conditions for making things are created when machines, facilities, and people work
together to add value without generating any waste." He conceived methodologies and
techniques for eliminating waste between operations, between both lines and processes.
The result was the Just-in-Time method.
By practicing the philosophies of "Daily Improvements" and "Good Thinking, Good Products,
" the TPS has evolved into a world-renowned production system. Furthermore, all Toyota
production divisions are making improvements to the TPS day and night to ensure its
continued evolution.
Recently, the "Toyota spirit of making things" is referred to as the "Toyota Way." It has been
adopted not only by companies inside Japan and within the automotive industry, but in
production activities worldwide, and continues to evolve globally.
Sakichi Toyoda
(1867-1930)
Toyoda Power Loom equipped with a new weft-breakage automatic stopping
device (developed in 1896)
World's first automatic loom with a non-stop shuttle-change motion, the Type-G
Toyoda Automatic Loom (developed in 1924)
Kiichiro Toyoda
(1894-1952)
Drawing on his experience of introducing a flow production method using a chain
conveyor into the assembly line of a textile plant (completed in 1927) with a
monthly production capacity of 300 units, Kiichiro Toyoda also introduced this
method into the body production line at Toyota Motor Co., Ltd.'s Koromo Plant
(present day Honsha Plant), completed in 1938.
Type-G Automatic Loom assembly line
Toyota Standard Sedan Model AA announced in 1936
Eiji Toyoda (1913-)
By ensuring thorough implementation of jidoka and the Just-in-Time method, Eiji

Toyoda increased workers' productivity by adding value and realized the Toyota
Production System, which enabled Toyota to compete head-on with companies in
Europe and the U.S.
Taiichi Ohno
(1912-1990)
With strong backing from Eiji Toyoda, Taiichi Ohno helped establish the Toyota
Production System, and built the foundation for the Toyota spirit of "making things"
by, for example, creating the basic framework for the Just-in-Time method.
Illustration of the Toyota Production System

Producing and delivering ordered vehicles in a timely manner

Toyota Production

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Just-in-Time Philosophy of complete elimination of waste

- Why use a supermarket concept?

Jidoka Manufacturing high-quality products

Jidoka and Visual Control

An andon problem display board that communicates abnormalities

The origin of the Toyota Production System

Type-G Automatic Loom assembly line

Toyota Standard Sedan Model AA announced in 1936

Eiji Toyoda (1913-)

By ensuring thorough implementation of jidoka and the Just-in-Time method, Eiji

Illustration of the Toyota Production System

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