TOYOTA PRODUCTION SYSTEM

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					TOYOTA PRODUCTION
SYSTEM




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Vision
 Contribute to Indian industry and economy
  through technology transfer, human resource
  development and vehicles that meet global
  standards at competitive price.
 Contribute to the well-being and stability of team
  members.
 Contribute to the overall growth for our business
  associates and the automobile industry.




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Mission
 Our mission is to design, manufacture and market
 automobiles in India and overseas while
 maintaining the high quality that meets global
 Toyota quality standards, to offer superior value and
 excellent after-sales service. We are dedicated to
 providing the highest possible level of value to
 customers, team members, communities and
 investors in India.




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7 Principles of Toyota
Production System
 Reduced setup time
 Small-lot production
 Employee Involvement and Empowerment
 Quality at the source
 Equipment maintenance
 Pull Production
 Supplier involvement



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TOYOTA PRODUCTION SYSTEM




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Production System




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JUST-IN-TIME
 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.




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KANBAN CONCEPT
 Meaning- Sign, Index Card
 It is the most important Japanese concept opted by
  Toyota.
 Kanban systems combined with unique scheduling
  tools, dramatically reduces inventory levels.
 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.

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Just-in-time --- Benefits
 Set up times are significantly reduced in the
  warehouse.
 The flows of goods from warehouse to shelves are
  improved.
 Employees who possess multiple skills are utilized
  more efficiently.
 Better consistency of scheduling and consistency of
  employee work hours.
 Increased emphasis on supplier relationships



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JIDOKA
 Jidoka (meaning ‘autonomation’)-a term used in Lean
  manufacturing meaning "automation with a human
  touch."
 It is a quality control process used in the Toyota
  Production System which applies the following four
  principles:

   Detect the abnormality.
   Stop.
   Fix or correct the immediate condition.
   Investigate the root cause and install a countermeasure.


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Jidoka




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Lean Manufacturing
 Most important concept of Toyota Production System
 A management philosophy focusing on reduction of
 the seven wastes to improve overall customer value.




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Key Principles
 Pull processing products are pulled from the consumer end
  (demand), not pushed from the production end (Supply)
 Perfect first-time quality  quest for zero defects, revealing &
  solving problems at the source
 Waste minimization  eliminating all activities that do not add
  value & safety nets, maximize use of scarce resources (capital,
  people and land)
 Continuous improvement  reducing costs, improving quality,
  increasing productivity and information sharing
 Flexibility  producing different mixes or greater diversity of
  products quickly, without sacrificing efficiency at lower volumes
  of production
 Building and maintaining a long term relationship with
  suppliers through collaborative risk sharing, cost sharing and
  information sharing arrangements.


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seven wastes to improve overall customer
value [ MUDA ]

  Transportation
  Inventory
  Motion
  Waiting time
  Over-production
  Processing Itself
  Defective Product (Scrap in manufactured
   products or any type of business.)

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Other Toyota Production
Concepts
 Heijunka (Production Smoothing)
 Kaizen (Continuous Improvement)
 Poke-Yoke (to avoid inadvertent errors)
 Andon (Signboard)
 Mura,Muri




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Heijunka
(Production Smoothing)
  Heijunka is Japanese term that refers to a system of
   production smoothing designed to achieve a more even
   and consistent flow of work.
  Heijunka as a concept is closely related to lean
   production and just in time manufacturing.
  A related visual scheduling board known as a heijunka
   box is often used in achieving heijunka style
   efficiencies.
  The use of heijunka as well as broader lean production
   techniques helped Toyota massively reduce vehicle
   production times as well as inventory levels during the
   1980s.

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Kaizen
 Meaning- Continuous Improvement
 Kaizen refers to a workplace 'quality' strategy and related to
  various quality-control systems.
 It aims to eliminate waste (defined as "activities that add
  cost but do not add value").
 Kaizen is a daily activity whose purpose goes beyond
  improvement. It is also a process that, when done correctly,
  humanizes the workplace, eliminates overly hard work
  (both mental and physical.
 It teaches people how to perform experiments using the
  scientific method and how to learn to spot and eliminate
  waste in business processes.


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Poke-Yoke
 Poka-yoke (means "fail-safing" or "mistake-proofing"
  —
 avoiding (yokeru) inadvertent errors (poka)) is a
  behavior-shaping constraint, or a method of
  preventing errors by putting limits on how an
  operation can be performed in order to force the
  correct completion of the operation.




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Andon (Signboard)
 Andon is a manufacturing term referring to a signboard incorporating
    signal lights, audio alarms, and text or other displays installed at a
    workstation to notify management and other workers of a quality or
    process problem.
   The alert can be activated manually by a worker, or may be activated
    automatically by the production equipment itself. Typically, it will
    incorporate both a visual indicator and an audible alarm.
   An Andon system is one of the principle elements of the Jidoka
    quality-control method pioneered by Toyota and now part of the Lean
    methodology.
   It gives the worker the ability to stop production when a defect is
    found, and immediately call for assistance.
   Work is stopped until a solution has been found out. The alerts may be
    logged to a database so that they can be studied as part of a
    continuous-improvement program.
   The system will typically indicate where the alert was generated, and
    may also provide a description of the trouble.
   Modern Andon systems can include text, graphics, or audio elements.
   Audio alerts may be done with coded tones, music with different tunes
    corresponding to the various alerts, or pre-recorded verbal messages.

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Mura , Muri
Mura
 Mura is a Japanese term for unevenness.
 It is also a key concept in the Toyota Production System and is one of
  the three types of waste (Muda, Mura, Muri) it identifies. Waste
  reduction is an effective way to increase profitability.

Muri
 Muri is a Japanese term for overburden or unreasonableness.
 It is also a key concept in the Toyota Production System and is one of
  the three types of waste (Muda, Mura, Muri) it identifies. Waste
  reduction is an effective way to increase profitability.
 Muri can be avoided through standardised work.




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Conclusion
 A Production System that is steeped in the philosophy
   of the complete elimination of all wastes and that
     penetrates all aspects of production with this
 philosophy in pursuit of the most efficient production
                        method.




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