The Toyota Production System

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1 Historical View
2 Performance measures
3 Elements of TPS
4 Six Eras of Manufacturing Practice
5 Difficulties with Implementation

J T. Black –1, 2

1. Form Cells
Sequential operations, decouple operator from machine, parts in families, single piece flow within cell


2. Reduce Setup
Externalize setup to reduce down-time during changeover, increases flexibility


J T. Black – 3, 4


3. Integrate quality control
Check part quality at cell, poke-yoke, stop production when parts are bad


4. Integrate preventive maintenance
worker maintains machine , runs slower


J T. Black – 7, 8


7. Reduce WIP
Make system reliable, build in mechanisms to self correct


8. Build Vendor program
Propagate low WIP policy to your vendors, reduce vendors, make on-time performance part of expectation