Decoding the Dna of the Toyota Production System

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Key Concepts
TPS’s four rules:
1.Rule 1 How People Work: all work shall be highly specified as to content, sequence, timing and outcome 2.Rule 2 How people connect: every customer-supplier connections must be direct, and there must be an unambiguous yes-or-no way to send request and receive responses 3.Rule 3 How the Production line is constructed: the pathway for every product and service must be simple and direct 4.Rule 4 How to improve: any improvement to processes, worker/machine connections, or flow path must be made through the scientific method, under teacher’s guidance, and at the lowest possible organizational level ➢Scientific method: a process for experimentation that is used to explore observations and answer questions in order to search for cause and effect relationships in nature. Observation, hypothesis testing and prediction.

Analytical Critic
Many manufacturing industries such as aerospace, consumer products, metals processing and industrial products had tried to adopt the TPS in their factories. But they have failed and get frustrated. The essence of the TPS could be in the system itself, the connections, activities and production flows. Also the great flexibility of their operations and this push the system to innovate and improve. The scientific method plays an important role inside the improvements and creation of any new methodology. Toyota uses a rigorous problem-solving process that integrates the sm. The system simulates workers ad managers to engage in the kind of experimentation that is widely recognized as the cornerstone of a learning organization. The four rules guide the design, operation and improvement of every activity, connections, and pathway for every product and service. The output of an ideal person, group of people, or machine is very specifically and clear. This kind of knowledge helps Toyota to reduce batches. The rules make workers capable and responsible for doing and improving their own work, by...
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