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    Service Level Quality - Standards, Measures, Monitoring & Enhancing-An Overview. OF Lean Manufacturing Toyota

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    The document provides an overview of lean manufacturing and the Toyota Production System. It discusses the origins and founders of TPS, how it developed after World War 2 to focus on reducing waste and costs. Key aspects of lean manufacturing covered include the 5S methodology, just-in-time production, setup time reduction, and the elimination of muda, muri and mura.

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    Service Level Quality - Standards, Measures, Monitoring & Enhancing-An Overview. OF Lean Manufacturing Toyota

    Uploaded by

    ladchaitanya
    40 views15 pages
    The document provides an overview of lean manufacturing and the Toyota Production System. It discusses the origins and founders of TPS, how it developed after World War 2 to focus on reducing waste and costs. Key aspects of lean manufacturing covered include the 5S methodology, just-in-time production, setup time reduction, and the elimination of muda, muri and mura.

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    Lean Production

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    The document provides an overview of lean manufacturing and the Toyota Production System. It discusses the origins and founders of TPS, how it developed after World War 2 to focus on reducing waste and costs. Key aspects of lean manufacturing covered include the 5S methodology, just-in-time production, setup time reduction, and the elimination of muda, muri and mura.

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    © All Rights Reserved
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    Download as pptx, pdf, or txt
    40 views15 pages

    Service Level Quality - Standards, Measures, Monitoring & Enhancing-An Overview. OF Lean Manufacturing Toyota

    Uploaded by

    ladchaitanya
    The document provides an overview of lean manufacturing and the Toyota Production System. It discusses the origins and founders of TPS, how it developed after World War 2 to focus on reducing waste and costs. Key aspects of lean manufacturing covered include the 5S methodology, just-in-time production, setup time reduction, and the elimination of muda, muri and mura.

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    of 15

    SERVICE LEVEL QUALITY STANDARDS, MEASURES, MONITORING & ENHANCING- AN

    OVERVIEW.
    OF
    LEAN MANUFACTURING

    TOYOTA
    BY
    History:
    Toyota's origins lie in the Japanese weaving industry when Sakichi
    Toyoda invented the world's first automatic loom and, subsequently,
    set up the Toyoda Spinning and Weaving Company in 1918.

    His invention reduced defects and increased yields since a loom


    stopped and would not go on producing imperfect fabric and using up
    thread after a problem occurred.

    This principle of designing equipment to stop automatically and


    call attention to problems immediately (jidoka) remains crucial to the
    Toyota Production System today.

    At Toyota Motor Company, TAICHII OHNO andSHIGEO


    SHINGO, began to incorporate Ford production and other
    techniques into an approach called Toyota Production System
    or Just in Time. They recognized the central role of inventory.
    Founders of the Toyota Production
    System (TPS)

    SHIGEO SHINGO
    TAIICHI OHO Pioneer of TPS and
    One of the originators of Toyota Industrial Engineer
    Production System extraordinaire
    Toyota Production System
    After World War II, Toyota was almost bankrupt.
    Post war demand was low and minimising the cost per unit
    through economies of scale was inappropriate.
    This led to the development of demand-led pull systems.
    The Japanese could not afford the expensive mass production
    facilities of the type used in the USA so they instead focused on
    reducing waste and low cost automation.
    Likewise, Toyota could not afford to maintain high inventory levels.
    LEAN MANUFACTURING

    Lean manufacturing or lean production, often simply "lean", is a systematic


    method for the elimination of waste (MUDA") within a manufacturing system.
    Lean also takes into account waste created through overburden (MURI") and
    waste created through unevenness in work loads (MURA"). Working from the
    perspective of the client who consumes a product or service, "value" is any
    action or process that a customer would be willing to pay for.
    LEAN MANUFACTURING

    Lean manufacturing is a management philosophy derived mostly from


    the TOYOTA PRODUCTION SYSTEM (TPS) (hence the term Toyotism
    is also prevalent) and identified as "lean" only in the TPS is renowned for
    its focus on reduction of the original Toyota seven wastes to improve
    overall customer value, but there are varying perspectives on how this is
    best achieved. The steady growth of TOYOTA, from a small company to
    the world's largest automaker, has focused attention on how it has
    achieved this success.
    Features of Lean Production
    About Lean Manufacturing
    Arose in Toyota Japan as the Toyota Production
    System
    Replacing complexity with simplicity
    A philosophy, a way of thinking
    A process of continuous improvement
    Emphasis on minimising inventory
    Focuses on eliminating waste, that is anything that
    adds cost without adding value
    Often a pragmatic choice of techniques is used
    Toyota Production System
    Technologies and practices can be copied.
    Most of the philosophies and techniques are widely
    disseminated.
    However, Toyota remains at the forefront, primarily because it is a
    learning organisation.
    Problem solving methods are applied routinely and are
    completely ingrained.
    The employees are continually engaged in Kaizen (continuous
    improvement).
    Many aspects of TPS are based upon embedded tacit
    knowledge.
    Methods for Elimination of Waste
    1. 5S
    2. Group technology
    3. Quality at the source
    4. JIT production
    5. Kanban production control
    system
    6. Minimized setup times
    7. Uniform plant loading
    8. Focused factory networks
    Minimizing Waste 5s
    Good factories develop beginning with
    the 5Ss. Bad factories fall apart
    beginning with the 5 Ss.
    - Hirouki Hirano
    Japanese Translation English
    Seiri Proper arrangement Sort
    Seiton Orderliness Simplify
    Seiso Cleanliness Sweep
    Seiketsu Cleanup Standardize
    Shitsuke Discipline Sustain
    Minimizing Waste: JIT
    Only produce whats needed
    The opposite of Just In Case
    philosophy
    Ideal lot size is one
    Minimize transit time
    Frequent small deliveries
    Minimizing Waste Setup Times
    Long setup times drive:
    Long production runs
    Large lots
    Long lead times
    JIT requires small lots and minimum kanbans:
    Setup reduction
    Focused efforts
    Problem solving
    Flexible equipment
    Summary and Conclusions
    Lean Production is the set of activities that achieves
    quality production at minimum cost and inventory.
    The flow of material is pulled through the process by
    downstream operations.
    Lean originated with the Toyota Production System
    and its two philosophies elimination of waste, and
    respect for people.
    THANK YOU

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