Toyota Production Systems

Duration

2 days

Introduction

Toyota Production System (TPS) was pioneered by Eiji Toyoda and Taiichi Ohno at the Toyota motor company in Japan. The rise of Japan to its current economic pre-eminence quickly followed, as other companies and industries copied this remarkable system. Manufacturers around the world are now trying to embrace this innovative system, but they are finding the going rough.

TPS is not just a system of production but a totality approach of productivity and quality improvements which involved human desires and mentality changes as well.

This training session intends to provide a detailed view of TPS and its application. Elements for successful implementation will be given and elaborated during the training session with references made based on participant’s business nature.

Objectives

After attending the course, participants should be able to:

• Define the TPS requirements for implementation in the factory.
• Apply JIT production concept to control and regulate production volume
• Identify Wastes in production.
• Develop effective workforce to achieve better production in less resources.
• Application of SMED to reduce setting up time.
• Apply visual management to facilitate production flow and control.
• Develop a quality workforce to support TPS.
• Develop implementation plan to work towards TPS for the company.

Day 1

• Overview of Toyota Production Systems (TPS)
• What is Toyota Production Systems (TPS)?
• Linkages between production, R & D , Sales & Marketing and management.
• Basic Ideas and Frame work.
• Cost reduction principles – Cut pay?
• 14 principles of TPS.
• Gap Analysis of your current status compared to TPS practices
• Develop actions required.
• 7 Wastes in production.
• 7 wastes details
• Analysis of wastes.
• Stratification of wastes/losses
• Workshop: Present your findings in the class.
• Basic principles: Quality Management in manufacturing.
• Quality assurance – ship good units only to next process (customers)
• Respect for Humanity- explore human capabilities to fullest.
• Workshops: Application of tools to develop above principles in your factory.
• Two main pillars for TPS to ensure continuous flow of production or leveled production.
• Application of JIT.
• Concept of JIT.
• Elements required to implement JIT
• JIT implementation-Kanban Application.
• What is Kanban?
• Rules for Kanban application.
• Development of Kanban system.
• Application Kanban structure.
• Workshop : Develop kanban structure for your company and rules for Kanban application.
• Autonomation (Jidoka) application.
• Examples of Jidoka implementation.
• Ingredients for successful Jidoka application.
• Culture required for Jidoka implementation.
• Automatic defect control.
• Games and exercise to illustrate JIT application.
• Real life practices on Jidoka.

Workshop: Define your suitable areas for Jidoka application.

End of Day 1

Day 2

• Flexible Work Force (Shojinka) and Creative Thinking Workforce (Soikufu).
• Meaning of flexible workforce.
• Multitasking versus multiplexing
• Employees Quality education and Skills enhancement.
• Tools to develop creative thinking workforce.
• Kaizen application.
• Tools to develop and encourage kaizen
• Exercise : Develop the quality training matrix for employees.
• Workshop: Set up rules and regulation and tools to develop employee’s creative thinking.
• Level production concepts
• What is level production?
• Production volume and planning process.
• Balancing line flow
• Tools for balancing techniques
• Case study on line balancing techniques for a assembly line.
• Applicable tools to balance the line such as MMAC (Man Machine Activity Chart) application.
• Workshop: Develop enhance workflow using details from MMAC
• SMED application.
• SMED (Single Minute Exchange of Die) principles.
• Examples of SMED in the line.
• Set up time reduction.
• Internal and External Change Over
• Workshop: Application examples and improvement to be performed on your selected process and areas.
• Standard operation and Cell production.
• Meaning of Standard Operation.
• Standard procedure and time definition.
• Enhancing performance using standard operation using Kaizen.
• Line production concept.
• Cell production concept and application
• Weaknesses and strengths for Line and Cell production.
• Process Layout versus Product Layout.
• Workshop.
• Visual Management and Mistake Prevention (POKA YOKE).
• Visual management in production line.
• Types of visual management.
• Poka Yoke Definition and Application.
• Examples of Poka Yoke in Factory and Daily Life.
• Exercise: Develop a suitable visual management and Poka Yoke in your work place.
• Conclusion.
• Develop the action plan to working towards lean and effective production environment using TPS.

End of Day 2.

Who Should Participate

This is a basic session for everyone who is interested to implement TPS in the production floor. The target audiences include Managers, Engineers, Supervisors and planners from Production, Quality and R & D departments.

Methodology

This Course will be conducted in lecture and Workshop Format where all participants need to work in workshops which geared towards establishing a lean and efficient production environment through the use of TPS. Videos on TPS and other related tools will be given at appropriate time frame.

Programme scope, delivery arrangements and suitability are confirmed during enquiry.