A Fast Take A Look At The Toyota Manufacturing System - TPS

A Fast Take A Look At The Toyota Manufacturing System - TPS

Toyota is at present the worlds leading automobile manufacturer, producing consistent higher performing and less expensive cars than any of the foremost American brands. How do they achieve this commentable feat? Is there some secret sauce to their method?

Effectively, yes, there may be some secret sauce. Nevertheless it isn't so secret - it's actually pretty well documented. It is called the Toyota Production System, and I would like to elucidate a little about it today.

TPS is a fully built-in socio-technical system comprising of it is administration rules, company philosophy, and manufacturing practices. Originally often known as "just in time" (or JIT), it draws upon the work of the founders of Toyota, his son, and an engineer - which in turn drew their inspiration from Henry Ford. The Toyota staff got here to America to look at the Ford manufacturing methods, but were decidedly unimpressed with the whole operation. From that experience, and observations of an automatic drink resupply system within the supermarket, they shaped the ideas of TPS.

The target of TPS is to reduce waste, inconsistency, and overburden. These are embodies in the Japanese terms muda, mura, and muri. The process ought to deliver the required results easily - with out inconsistencies; whereas being as flexible as needed with out overburdening the employees, which might result in waste.

What's waste as addressed by TPS? 7 kinds have been identified:

Movement (of man or machine)
Ready (of man or machine)
Processing itself
Stock (raw supplies)
Correction (rework and scrap)

The physical cost of correcting defective products or disposing of them is obvious, however the remainder may need explaining. Movement creating lean culture waste might discuss with extra actions required on the part of the meeting line worker who should physically carry gadgets from one machine to another - which could possibly be reduced by connecting the machines. Waiting waste refers to the time when one machine lies unused, because it is nonetheless "ready" for an additional process within the manufacturing line to complete - you may't put the lights on the automobile till the paint has dried, for instance. Wastage of raw materials can occur because the design of the machine is such that it requires 1m squared of metal to cut a single 50cm squared form - with proper designing, these could combined into 1 larger sheet with less waste cut.