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

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

Toyota is currently the worlds leading automotive manufacturer, producing constant better performing and less expensive vehicles than any of the major American brands. How do they achieve this remarkable feat? Is there some secret sauce to their formulation?

Effectively, yes, there's some secret sauce. But it isn't so secret - it's actually pretty well documented. It's called the Toyota production planning and control System, and I would like to clarify a little bit about it today.

TPS is a fully built-in socio-technical system comprising of it is management ideas, company philosophy, and manufacturing practices. Originally known as "just in time" (or JIT), it attracts upon the work of the founders of Toyota, his son, and an engineer - which in flip drew their inspiration from Henry Ford. The Toyota employees got here to America to observe the Ford manufacturing methods, but have been decidedly unimpressed with the whole operation. From that have, and observations of an automatic drink resupply system in the supermarket, they formed the rules of TPS.

The objective of TPS is to reduce waste, inconsistency, and overburden. These are embodies within the Japanese terms muda, mura, and muri. The method ought to deliver the required results easily - without inconsistencies; whereas being as flexible as needed without overburdening the employees, which would end in waste.

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

Movement (of man or machine)
Waiting (of man or machine)
Processing itself
Inventory (uncooked materials)
Correction (rework and scrap)

The physical value of correcting defective merchandise or disposing of them is apparent, but the rest may have explaining. Motion waste could confer with extra actions required on the part of the meeting line worker who must 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 another process within the manufacturing line to complete - you may't put the lights on the automotive till the paint has dried, for instance. Wastage of raw supplies can occur because the design of the machine is such that it requires 1m squared of metal to chop a single 50cm squared form - with correct designing, these could combined into 1 bigger sheet with much less waste cut.