The Toyota Production System ( Tps )

The case describes the details about the production process of Toyota and the principles they are following, like JIT & Jidoka in Toyota Production System (TPS), heijunka & kaizen. How they have control the cost, maintain quality through process

Overview: The Toyota Production System has long been hailed and admired as the source of Toyota’s outstanding performance as a manufacturer. TPS aims to eliminate waste, reduce defects and maximize flow. TPS aims to increase efficiency and productivity by employing a unique production system that cuts costs through continuous improvement. Long term goal is to yield sharp reductions in product development and manufacturing lead times. Toyota want to be the industry best and they stand behind their culture to share the wealth of how they do it.

Manufacturing operations are crucial to our company. To be successful and satisfy consumers, Jaguar Land Rover must have an efficient line of production. The operations management team is primarily concerned with overseeing, designing, and controlling the process of the business operations in the production of our goods. While we have been prosperous in the past, it is critical that we change our production process from just-in-case manufacturing to just-in-time manufacturing. Not only will implementing this new practice allow us to maintain our success, it will also allow us to surpass it and achieve an entire new level of prosperity.

Lean manufacturing based on the Toyota production system (TPS) “changed the final assembly into a mixed model final assembly system to level the demand on their suppliers, converted the linear subassembly lines into U-shaped subassembly cells and redesigned the job shop into manufacturing cells. Final assembly operates with a ‘takt’ time, and the cells are designed to have a cycle time slightly less than the ‘takt’ time and to operate on a ‘make one, check one, and move one on’(MO-CO-MOO basis)” (Black, 2007, p. 3639).

Toyota’s product system is considered as benchmark for most of automobile companies .error free and flexible assembly lines shows how innovative

Lean manufacturing originated long before Toyota and Ford, however the thought that it originated with Toyota is flattering since they are the ones who perfected it. By creating the Toyota Production System (TPS), Toyota found a better way to produce large quantities of product efficiently with eliminating the waste factor and while cutting down cost. Taiichi Ohno a former Toyota vice president promoted the idea of JIT (Just-in-Time) which means “producing the necessary units in the necessary quantities at the necessary time.” (Monden) Which leads to Toyota’s ultimate goal in the TPS is to improve productivity for better return in investment. To have continuous flow in a production system Toyota sought out to achieve the concept of JIT and autonomation . Since the TPS is what creates the parts who monitors the JIT system? The kanban system which is an informational system that controls quantities being produce in each process. As the discussion carries on throughout this paper about Toyota and their use of the kanban system the topic

Toyota SCM based on Keiretsu structure that it is working with dependent suppliers that ensure high quality of raw materials. Toyota develops this SCM by creating assembly system which base on Pull demand and just in time operation strategy.

The principle of Just in Time (JIT) is to produce and/or deliver the right quantity of products, of the right quality, within the right time and at the right place in order to increase productivity, efficiency and to decrease costs and wastes associated with overproduction. According to International Journal of Economics, Business and Finance (2013), JIT consists of two main elements which must be integrated together to function in harmony including human resources, planning based on the elimination of wastes.

"Just-in-Time" means making "only what is needed, when it is needed, and in the amount needed (Toyota Global Site 2014)." Just-in-Time or zero inventory was developed in the 1950’s in Japan, and it can be traced to American manufacturing to the early 1980’s. The goal of zero inventories was to have limited amount of inventory available. This concept brought widespread changes in how manufacturers conducted business. It removed waste, but supplied parts only as and when needed. The Just in Time cut the need for each stage of the manufacturing process to store inventory (The Economist 2009).

In this paper we will discuss Toyota’s Production System and how it works with the strategy of their business. We will define their mission and visions goals and their core principles as it applies to their company. This paper will also discuss their basic approaches and general practices. It is also important to understand what the Toyota Production System entails and how Lean operations began.

Toyota is famous for their production system called Just-In-Time inventory (JIT) strategy which is referred as a production strategy to employ an increase in the level of efficiency and reduce waste by receiving goods only in the form they are required in the production process; this reduces inventory costs. This method calls for the producers to be capable of forecasting demand accurately. The main benefits associated the Just-In-Time inventory strategy includes reducing the setup

Toyota Motor Company has risen to become the global model for efficient auto manufacturing through the use of operations management. Since the late 1980’s, The Toyota Production System has been employing several techniques such as hi-tech automation, line segmentation, and inter-segment buffers to reach optimal efficiency.

All the parts for a single garment are advanced through the production line together by means of a hanging carrier that travels along an overhead conveyor. The overhead rail system consists of the main conveyor and accumulating rails for each work station. The overhead conveyor operates much like a railroad track. Carriers are moved along the main conveyor and switched to an accumulating rail at the work station where an operation is to be performed. At the completion of an operation the operator presses a button, and the carrier moves on to the next operation. Most unit production systems are linked to a computer control center that routes and tracks production and provides up-to-the-minute data for management decisions. The

Just-In-Time is the assessment of product production time and immediate resource requirements to conduct uninterrupted product production within a prescribed period (Toyota Motor Manufacturing, 2015).

The idea of Just In Time originated in Japan. Actually this type of inventory/production was originally known as the "Toyota Production System". A man by the name of Taiichi Ohno is credited as the person who first came up with this system. He looked at the Western industries and found that the manufacturers would set up their manufacturing lines to produce a large quantity of one product before stopping and and switching to a different product. They also would order and stock an overabundance of inventory so that the right parts were always on hand.