A Fast Take a look at the Toyota Manufacturing System – TPS

Toyota is at present the worlds leading automotive producer, producing consistent higher performing and more cost effective lean project management cars than any of the major American brands. How do they achieve this commentable feat? Is there some secret sauce to their formula?

Well, yes, there may be some secret sauce. But it is not so secret – it’s truly pretty properly documented. It is called the Toyota Production System, and I would like to explain somewhat about it today.

TPS is a completely integrated socio-technical system comprising of it’s administration rules, firm philosophy, and manufacturing practices. Initially known as «just in time» (or JIT), it attracts upon the work of the founders of Toyota, his son, and an engineer – which in flip drew their inspiration from Henry Ford. The Toyota workers got here to America to look at the Ford production methods, but were decidedly unimpressed with the whole operation. From that have, and observations of an automated drink resupply system in the supermarket, they shaped the ideas of TPS.

The target of TPS is to reduce waste, inconsistency, and overburden. These are embodies in the Japanese terms muda, mura, and muri. The process should deliver the required results smoothly – with out inconsistencies; while being as versatile as needed without overburdening the workers, which would lead to waste.

What’s waste as addressed by TPS? 7 kinds have been recognized:


Movement (of man or machine)

Ready (of man or machine)


Processing itself

Stock (uncooked materials)

Correction (rework and scrap)

The bodily cost of correcting defective merchandise or disposing of them is apparent, but the remainder may have explaining. Movement waste could seek advice from further actions required on the a part of the meeting line worker who must physically carry gadgets from one machine to another – which may very well be reduced by connecting the machines. Waiting waste refers to the time when one machine lies unused, because it is nonetheless «waiting» for an additional course of within the production line to finish – you can’t put the lights on the car till the paint has dried, for instance. Wastage of uncooked materials can occur because the design of the machine is such that it requires 1m squared of metal to cut a single 50cm squared form – with correct designing, these could mixed into 1 larger sheet with much less waste cut.