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TPS House
This simple house was used to visually describe the Toyota Production System. All other components were inherit to the system. Ex: Safety, Customer First, Heijunka (Leveled production), etc. All other versions of the TPS house should be used to clarify your understanding. Based on our experience we have added details, which you might find useful.

Highest

Quality,
 Lowest
Cost,
Shortest
 Lead
Time


JIT


Jidoka


Standardiza)on


effective

partnerships, inc.
“Your process improvement partners”

TPS House
Continuing with the symbolism of the house we have 5 components of the house. I.  Foundational II.  Jidoka Walls III. JIT Walls IV. Customer Satisfaction Roof V.  People The order of the building represents the sequence of construction but TPS always starts with the people.

Customer
Sa)sfac)on


JIT


Jidoka


Founda)onal


effective

partnerships, inc.
“Your process improvement partners”

TPS House
The foundation of the TPS house is the most overlooked component of TPS / Lean Management. Just like a real house the foundation needs to be large enough to support the walls and roof. The invested efforts on the foundation will assist in the sustainability of your system. We have made the foundation much thicker than the original to capture the implied understandings. The foundation consists of: 1.  Customer First – A company exists because somebody is willing to pay for a service or product. Only the customer can determine the value of the product or service. 2.  Respect for Humanity – Creating work environments that are safe and promote job enrichment. Utilizing the full talents of all Associates. 3.  Genba - Actual worksite or workplace where the value is created. 4.  Genchi Genbutsu – Actual place, actual thing also translated as “go and see.” Spend time observing the process versus hearing about it. 5.  Stability - Refers to reliable machines, workforce and material. Kaizen is not a substitution for maintenance. 6.  Standards – Agreed upon quality levels and ways of working or work instructions. 7.  Heijunka – Leveled production based on the market and capacity of the company. 8.  Safety – Always considered in each process

Founda)onal

effective partnerships, inc.
“Your process improvement partners”

TPS House
The first pillar of the TPS house was created by Sakiichi Toyoda. His philosophy was quality should be built in not inspected in. Autonomation or automation with a human touch means automatic equipment should not continue to run while making defects. Jidoka also helps to create a sense of urgency and drive immediate countermeasures. Components of jidoka are: 1.  Poka yoke – A device which prevents mistakes from happening. Referred to as full proofing or bullet proofing. The goal is to prevent defects from being passed on. This will eliminate reworked or scraping products or services. 2.  Andon – A warning system to tell others of a problem. A light, sound or pull cord system to call attention to problems. The purpose is to prevent defects from being passed on by visually seeing where problems are coming from, how often and request help. 3.  5S – Seiri (Sort out), Seiton (Set in place, arrange), Seiso (Sweep, wash, cleaning), Seiketsu (Sanitize) and Shitsuke (Sustain, discipline). 5S has effects on safety, quality and productivity. 4.  A3 Reports– Process of writing proposals and problem solving in both A3 and A4 sized papers. Ensures fundamentals are not skipped. 5.  5 Why’s – Process of getting to the root cause of a problem by asking why enough times until the reason is out of your control. 6.  Visual Control – Any tools such as production boards that tell you the normal from abnormal conditions. effective partnerships, inc.

“Your process improvement partners”

Jidoka


TPS House
The second pillar of the TPS house was created by Kiichiro Toyoda and expanded on by Taiichi Ohno. Due to limited capital JIT was created to produce vehicles on an as...
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