Toyota Production System (TPS)

TOYOTA PRODUCTION SYSTEM
(TPS)

PREPARED BY: MUHAMAD LUQMAN BIN ZAHARI
(2014674904)
ALI IMRON BIN IMAM SHOBAR (2013737935)
DEFINITION

Toyota Production System (TPS) is an integrated
socio-technical system developed by Toyota, that its
management philosophy and practices.
Organizes manufacturing and logistics for

automobile manufacturer, including interaction with
supplier and customers
OBJECTIVES

To design out overburden and inconsistency.
To eliminate waste material.
To offer superior value and excellent after-sales

service.
PRINCIPLES IN TPS / TOYOTA WAYS

Continuous improvement (kaizen).
Respect for people.
Long term philosophy - Look ahead to the future.
The right process will produce the right result Doing
it right the first time.
Add value to the organization by developing your
people and partners.
TOYOTA
PRODUCTION
SYSTEM
(HOUSE OF TOYOTA)
1.JIT
2.JIDOKA
3.HEIJUNKA
4.TPM
JUST-IN-TIME (JIT)

Just-in-Time (JIT) is an inventory strategy companies employ to
increase efficiency and decrease waste.
Produced according to what needed, when needed and how

much needed.
Strategy to improve return on investment by reducing

inventory and associated cost.
The process is driven by Kanban concept.

COMPARISON BETWEEN TRADITIONAL
AND JIT

KANBAN CONCEPT

The most important Japanese concept opted by
Toyota.
Enhances supplier/customer relationships and
improves the accuracy of manufacturing schedules.
A signal is sent to produce and deliver a new shipment
when material is consumed.
These signals are tracked through the refill cycle and
bring extraordinary visibility to suppliers and buyers.
JIDOKA

Jidoka (meaning autonomation) - a term used in
Lean manufacturing meaning "automation with a
human touch."
Machines able distinguish between good and bad
parts without being monitored by an operator.
When machine detect any defects, the machines
solves immediately.
Defects of products can be detected at an early stage,
therefore number of defect can be reduced greatly.
PRINCIPLES IN JIDOKA

Four principles:
1. Detect the abnormality.

2. Stop.
3. Fix or correct the immediate condition.
4. Investigate the root cause and install a
countermeasure.
COMPARISON BETWEEN AUTOMATION
AND JIDOKA AUTONOMATION

OTHERS TPS CONCEPT
5S
MURA
MURI KAIZEN
MUDA
TP
ANDON
S TPM
POKE HEIJUNK
YOKE A
5S

5s is the list of five Japanese words thats describe how
to organize work space for efficiency and
effectiveness, maintaining the area and item
sustaining the new order.
Seiri (Sort)
Seiton (Set in Order)
Seiso (Shine)
Seiketsu (Standardize)
HEIJUNKA // KAIZEN

Heijunka is Japanese term that Kaizen refers to a workplace
refers to a system of production 'quality' strategy and related to
smoothing designed to achieve a various quality-control systems.
more even and consistent flow of It aims to eliminate waste (defined
work. as "activities that add cost but do
Heijunka as a concept is closely not add value").
related to lean production and just Kaizen is a daily activity whose
in time manufacturing. purpose goes beyond improvement.
A related visual scheduling board It is also a process that, when done
known as a heijunka box is often correctly, humanizes the workplace,
used in achieving heijunka style eliminates overly hard work (both
efficiencies. mental and physical.
POKE YOKE // ANDON

Poka-yoke means "fail-safing" or Andon is a manufacturing term referring
to a signboard incorporating signal lights,
"mistake-proofing. audio alarms, and text or other displays
A poka-yoke is any mechanism installed at a workstation to notify
in a lean manufacturing process management and other workers of a
quality or process problem.
that helps an equipment
It gives the worker the ability to stop
operator avoid (yokeru) production when a defect is found, and
mistakes (poka). Its purpose is immediately call for assistance.
to eliminate product defects by Work is stopped until a solution has been
preventing, correcting, or found out. The alerts may be logged to a
database so that they can be studied as
drawing attention to human part of a continuous-improvement
errors as they occur. program.
MURA MURI MUDA // TPM

Mura is a Japanese term for TPM is a coordinated group of
unevenness. activities whose objective is to
Muri is a Japanese term for minimize production losses due to
overburden or unreasonableness. equipment failures, malfunctions
Muda is a Japanese term for waste. and low utilization through the
participation of workers at all
Waste reduction is an effective
levels of the organization.
way to increase profitability.
TPM involves the integration of
Can be avoided through
preventive maintenance and
standardised work.
predictive maintenance to avoid
emergency maintenance.
ADVANTAGES OF TPS

Produce products with high quality.
Low production cost more profit,
Product can be delivered on time.
Environmentally friendly less waste.
Ensure safety for workers and
consumers.
CONCLUSION

Toyota Production System is steeped in the philosophy
of the complete elimination of all wastes and penetrates all
aspects of production with its philosophy in pursuit of the
most efficient production method.

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TOYOTA PRODUCTION SYSTEM

Organizes manufacturing and logistics for

To eliminate waste material.

To offer superior value and excellent after-sales

Produced according to what needed, when needed and how

Strategy to improve return on investment by reducing

The process is driven by Kanban concept.

1. Detect the abnormality.

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