Toyota Production System

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TOYOTA PRODUCTION SYSTEM BASIC HANDBOOK

TABLE OF CONTENTS
Introduction & History of the Toyota Production System ........................ 3 Goals of the Toyota Production System. ................................................. 4 TPS Model Overview............................................................................5-6 Respect for People .................................................................................. 7 Focus Areas of TPS ................................................................................ 8 Eliminating Waste..........................................................................9-10 Quality .........................................................................................11-12 Cost. ................................................................................................. 13 Productivity....................................................................................... 14 Safety & Morale ................................................................................ 15 Jidoka . .............................................................................................16-18 Standardization……………………………………………………………….19 Just in Time ........................................................................................... 20 Pull Production………………………………………………………………..21 Kanban……………………………………………………………………..22-23 Level Production.................................................................................... 24 Takt Time. ............................................................................................. 25 Flow Production................................................................................26-28 Equipment Reliability ............................................................................. 29 Summary ............................................................................................... 30 Definition of Terms. ..........................................................................31-32

TPS Handbook
Art of Lean, Inc. www.artoflean.com

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INTRODUCTION
This handbook is intended to function as a simple guide that introduces key concepts related to the Toyota Production System. It is not intended as a complete reference manual or an implementation guide. The contents described within are merely provided to summarize the more familiar elements of the system in a concise manner. If you are looking for a more complete summary of the system then there are several published works that attempt to go into greater detail. Examples of summary works include “Toyota Production System” by Yasuhiro Monden, “A Study of the Toyota Production System from an Industrial Engineering Viewpoint” by Shigeo Shingo, “Toyota Production System: Beyond Large Scale Production” by Taiichi Ohno, and more recently, “The Toyota Way” and the accompanying field book by Jeff Liker.

BRIEF HISTORY OF THE TOYOTA PRODUCTION SYSTEM
The Toyota Production System (TPS) arose out of necessity in response to the circumstances surrounding the company. Many of the foundational concepts are old and unique to Toyota while others have their roots in more traditional sources. The oldest part of the production system is the concept of Jidoka which was created in 1902 by Toyoda founder Sakichi Toyoda. This concept pertains to notion of building in quality at the production process as well as enabling separation of man and machine for multi-process handling. The origins of this notion began in the Toyoda Spinning and Weaving company which was started by Sakichi Toyoda. Sakichi invented a loom that automatically stopped whenever it detected that a thread was broken. This stopped the process from created defective material. Later on in 1924 he created an automatic loom that allowed one person to operate multiple machines. The rights to manufacture the loom outside of Japan for were eventually sold to the Platt Brothers Ltd. in England. This money was then partially used to...
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