Toyota is at the moment the worlds leading automobile producer, producing consistent higher performing and more economical automobiles than any of the major American brands. How do they achieve this remarkable feat? Is there some secret sauce to their components?
Nicely, yes, there's some secret sauce. But it surely isn't so secret - it is truly pretty effectively documented. It is called the Toyota Production System, and I would like to elucidate just a little about it today.
TPS is a totally built-in socio-technical system comprising of it's management rules, company philosophy, and manufacturing practices. Initially known as "just in time" (or JIT), it draws upon the work of the founders of Toyota, his son, and an engineer - which in turn drew their inspiration from Henry Ford. The Toyota staff got here to America to watch the Ford manufacturing strategies, however had been decidedly unimpressed with the whole operation. From that experience, and observations of an automated drink resupply system within the supermarket, they fashioned the rules of TPS.
The objective of TPS is to reduce waste, inconsistency, and overburden. These are embodies within the Japanese phrases muda, mura, and muri. The method ought to deliver the required outcomes easily - with out inconsistencies; whereas being as versatile as necessary without overburdening the employees, which would lead to waste.
What is waste as addressed by TPS? 7 kinds have been identified:
Movement (of man or machine)
Waiting (of man or machine)
Stock (raw materials)
Correction (rework and scrap)
The bodily price of correcting defective products or disposing of them is obvious, but the remaining might have explaining. Motion waste may check with further actions required on the part of the meeting line employee who should physically carry gadgets from one machine to a different - which could be reduced by connecting the machines. Ready waste refers to the time when one machine lies unused, because it is nonetheless "ready" for another course of within the manufacturing line to complete - you may't put the lights on the automobile until the paint has dried, for instance. Wastage of uncooked supplies can occur because the design of the machine is such that it requires 1m squared of metal to cut a single 50cm squared shape - with correct designing, total productive maintenance tpm
these could mixed into 1 bigger sheet with much less waste cut.