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