TOYOTA PRODUCTION SYSTEM
STUDY GUIDE
TPS is a holistic system that integrates all aspects of production, from raw materials to finished goods, including suppliers and customers.
Pillars of the Toyota Production System (TPS)
- Just in Time (JIT): Produce only what is needed, when it is needed.
- Jidoka: Automation with a human touch. Equipment stops automatically when problems occur.
- Kaizen: Continuous improvement.
- Heijunka: Production leveling. Smooth production flow to avoid unevenness and waste.
- Respect for people: Empower and engage employees.
How are lead times estimated?
- Historical data: Analyze past production times for similar products
- Process mapping: Identify and time each step in the production process.
- Expert judgment: Consult with experienced engineers or production personnel.
What is takt time?
Takt time is calculated by dividing the total available production time by the number of units needed.
How much time is remaining to complete production?
480 minutes – 30 minutes – 15 minutes = 435 minutes
How many wastes are associated with the manufacturing process?
Seven (7)
What are some benefits of Heijunka?
- Facilitates Just-in-Time: By producing a leveled schedule, Heijunka makes it easier to implement JIT by ensuring a smooth flow of materials and finished goods.
- Reduces waste: By eliminating uneven production, Heijunka helps to reduce waste in the production process.
- Improves quality: By allowing for more focused attention on each product, Heijunka can help to improve product quality.
- Increases efficiency: By reducing waste and improving quality, Heijunka can help to increase overall production efficiency.
What does muri mean?
Muri means “unevenness” in Japanese. It refers to the uneven distribution of work which can lead to problems such as overburdening employees and quality defects.
What is affected when JIT principles of TPS fail?
- Supply Chain Imbalance: Without proper planning and coordination, JIT can lead to disruptions in the supply chain, causing shortages of materials and delays in production.
- Increased Costs: JIT requires careful inventory management, which can be costly if not implemented properly.
- Quality Issues: Without proper quality control procedures in place, JIT can lead to an increase in defects and customer dissatisfaction.
- Employee Stress: JIT can put pressure on employees to work quickly and efficiently, which can lead to stress and burnout.
