Diese Präsentation wurde erfolgreich gemeldet.
Wir verwenden Ihre LinkedIn Profilangaben und Informationen zu Ihren Aktivitäten, um Anzeigen zu personalisieren und Ihnen relevantere Inhalte anzuzeigen. Sie können Ihre Anzeigeneinstellungen jederzeit ändern.

What is TPS - Toyota Production System

2.594 Aufrufe

Veröffentlicht am

Here is my definition of Toyota Production System based on my 30 years experience working for Toyota Manufacturing and helping companies all over the World with Lean Transformation.

Veröffentlicht in: Leadership & Management
  • DOWNLOAD THIS BOOKS INTO AVAILABLE FORMAT (2019 Update) ......................................................................................................................... ......................................................................................................................... Download Full PDF EBOOK here { https://soo.gd/irt2 } ......................................................................................................................... Download Full EPUB Ebook here { https://soo.gd/irt2 } ......................................................................................................................... Download Full doc Ebook here { https://soo.gd/irt2 } ......................................................................................................................... Download PDF EBOOK here { https://soo.gd/irt2 } ......................................................................................................................... Download EPUB Ebook here { https://soo.gd/irt2 } ......................................................................................................................... Download doc Ebook here { https://soo.gd/irt2 } ......................................................................................................................... ......................................................................................................................... ................................................................................................................................... eBook is an electronic version of a traditional print book THIS can be read by using a personal computer or by using an eBook reader. (An eBook reader can be a software application for use on a computer such as Microsoft's free Reader application, or a book-sized computer THIS is used solely as a reading device such as Nuvomedia's Rocket eBook.) Users can purchase an eBook on diskette or CD, but the most popular method of getting an eBook is to purchase a downloadable file of the eBook (or other reading material) from a Web site (such as Barnes and Noble) to be read from the user's computer or reading device. Generally, an eBook can be downloaded in five minutes or less ......................................................................................................................... .............. Browse by Genre Available eBooks .............................................................................................................................. Art, Biography, Business, Chick Lit, Children's, Christian, Classics, Comics, Contemporary, Cookbooks, Manga, Memoir, Music, Mystery, Non Fiction, Paranormal, Philosophy, Poetry, Psychology, Religion, Romance, Science, Science Fiction, Self Help, Suspense, Spirituality, Sports, Thriller, Travel, Young Adult, Crime, Ebooks, Fantasy, Fiction, Graphic Novels, Historical Fiction, History, Horror, Humor And Comedy, ......................................................................................................................... ......................................................................................................................... .....BEST SELLER FOR EBOOK RECOMMEND............................................................. ......................................................................................................................... Blowout: Corrupted Democracy, Rogue State Russia, and the Richest, Most Destructive Industry on Earth,-- The Ride of a Lifetime: Lessons Learned from 15 Years as CEO of the Walt Disney Company,-- Call Sign Chaos: Learning to Lead,-- StrengthsFinder 2.0,-- Stillness Is the Key,-- She Said: Breaking the Sexual Harassment Story THIS Helped Ignite a Movement,-- Atomic Habits: An Easy & Proven Way to Build Good Habits & Break Bad Ones,-- Everything Is Figureoutable,-- What It Takes: Lessons in the Pursuit of Excellence,-- Rich Dad Poor Dad: What the Rich Teach Their Kids About Money THIS the Poor and Middle Class Do Not!,-- The Total Money Makeover: Classic Edition: A Proven Plan for Financial Fitness,-- Shut Up and Listen!: Hard Business Truths THIS Will Help You Succeed, ......................................................................................................................... .........................................................................................................................
       Antworten 
    Sind Sie sicher, dass Sie …  Ja  Nein
    Ihre Nachricht erscheint hier
  • DOWNLOAD FULL ▶ ▶ ▶ ▶ http://bit.ly/2XqaJas ◀ ◀ ◀ ◀
       Antworten 
    Sind Sie sicher, dass Sie …  Ja  Nein
    Ihre Nachricht erscheint hier
  • DOWNLOAD THAT BOOKS INTO AVAILABLE FORMAT (2019 Update) ......................................................................................................................... ......................................................................................................................... Download Full PDF EBOOK here { http://bit.ly/2m77EgH } ......................................................................................................................... Download Full EPUB Ebook here { http://bit.ly/2m77EgH } ......................................................................................................................... Download Full doc Ebook here { http://bit.ly/2m77EgH } ......................................................................................................................... Download PDF EBOOK here { http://bit.ly/2m77EgH } ......................................................................................................................... Download EPUB Ebook here { http://bit.ly/2m77EgH } ......................................................................................................................... Download doc Ebook here { http://bit.ly/2m77EgH } ......................................................................................................................... ......................................................................................................................... ................................................................................................................................... eBook is an electronic version of a traditional print book that can be read by using a personal computer or by using an eBook reader. (An eBook reader can be a software application for use on a computer such as Microsoft's free Reader application, or a book-sized computer that is used solely as a reading device such as Nuvomedia's Rocket eBook.) Users can purchase an eBook on diskette or CD, but the most popular method of getting an eBook is to purchase a downloadable file of the eBook (or other reading material) from a Web site (such as Barnes and Noble) to be read from the user's computer or reading device. Generally, an eBook can be downloaded in five minutes or less ......................................................................................................................... .............. Browse by Genre Available eBooks .............................................................................................................................. Art, Biography, Business, Chick Lit, Children's, Christian, Classics, Comics, Contemporary, Cookbooks, Manga, Memoir, Music, Mystery, Non Fiction, Paranormal, Philosophy, Poetry, Psychology, Religion, Romance, Science, Science Fiction, Self Help, Suspense, Spirituality, Sports, Thriller, Travel, Young Adult, Crime, Ebooks, Fantasy, Fiction, Graphic Novels, Historical Fiction, History, Horror, Humor And Comedy, ......................................................................................................................... ......................................................................................................................... .....BEST SELLER FOR EBOOK RECOMMEND............................................................. ......................................................................................................................... Blowout: Corrupted Democracy, Rogue State Russia, and the Richest, Most Destructive Industry on Earth,-- The Ride of a Lifetime: Lessons Learned from 15 Years as CEO of the Walt Disney Company,-- Call Sign Chaos: Learning to Lead,-- StrengthsFinder 2.0,-- Stillness Is the Key,-- She Said: Breaking the Sexual Harassment Story That Helped Ignite a Movement,-- Atomic Habits: An Easy & Proven Way to Build Good Habits & Break Bad Ones,-- Everything Is Figureoutable,-- What It Takes: Lessons in the Pursuit of Excellence,-- Rich Dad Poor Dad: What the Rich Teach Their Kids About Money That the Poor and Middle Class Do Not!,-- The Total Money Makeover: Classic Edition: A Proven Plan for Financial Fitness,-- Shut Up and Listen!: Hard Business Truths that Will Help You Succeed, ......................................................................................................................... .........................................................................................................................
       Antworten 
    Sind Sie sicher, dass Sie …  Ja  Nein
    Ihre Nachricht erscheint hier
  • If you want a girl to "chase" you, then you have to use the right "bait". We discovered 4 specific things that FORCE a girl to chase after you and try to win YOU over. copy and visiting...  http://ishbv.com/unlockher/pdf
       Antworten 
    Sind Sie sicher, dass Sie …  Ja  Nein
    Ihre Nachricht erscheint hier
  • FREE TRAINING: "How to Earn a 6-Figure Side-Income Online" ... ▲▲▲ https://tinyurl.com/y3ylrovq
       Antworten 
    Sind Sie sicher, dass Sie …  Ja  Nein
    Ihre Nachricht erscheint hier

What is TPS - Toyota Production System

  1. 1. 1Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN What is Toyota Production System? Introduction to TPS Marek Piatkowski – March 2017 Thinkingwin, Win, WIN
  2. 2. 2Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN Introduction - Marek Piatkowski  Professional Background  Toyota Motor Manufacturing Canada (TMMC) - Cambridge, Ontario from 1987-1994  TPS/Lean Transformation Consulting - since 1994  Professional Affiliations  TWI Network – John Shook, Founder  Lean Enterprise Institute (LEI) – Jim Womack  Lean Enterprise Academy (LEA) – Daniel Jones  CCM/CAINTRA – Monterrey, Mexico  SME, AME, ASQ, CME  Lean Manufacturing Solutions - Toronto, Canada http://twi-network.com
  3. 3. 3Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN
  4. 4. 4Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN The Most Studied Company in the World
  5. 5. 1987
  6. 6. 7 Production should take place with a little inventory as possible, preferably only the one component that is to be processed or assembled next.
  7. 7. 8Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN Stability GOAL: Highest Quality, Lowest Cost, Shortest Lead Time 1. Stable Manufacturing Processes 2. 100% Quality Parts Heijunka Standardized Work Kaizen Just-in-Time Jidoka Stop the line and fix the Problem Separate man’s work from machine’s work Continuous Flow Takt Time Pull System The Toyota House Toyota Production System (TPS)
  8. 8. 9Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN Toyota Sensei  Sensei (先生) is a Japanese title used to refer to or address teachers, professors, masters, coaches, professionals such as lawyers, doctors, politicians, clergyman and other figures of authority.  The word Sensei is also used to show respect to someone who has achieved a certain level of mastery in an art form or science or some other skill: accomplished novelists, musicians, and artists for example are addressed in this way.  The Japanese Sensei is a courtesy title for a man of respected stature.
  9. 9. 10Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN What is TPS – Toyota Production System?  Toyota Production System (TPS) is a practical expression of Toyota's people and customer-oriented philosophy.  This is not a rigid company-imposed procedure but a set of principles that have been proven in day-to-day practice over many years.  Many of these ideas have been adopted and imitated all over the world.  TPS has three desired outcomes:  To provide the customer with the highest quality vehicles, at lowest possible cost, in a timely manner with the shortest possible lead times.  To provide Toyota employees with work satisfaction, job security and fair treatment.  It gives the company flexibility to respond to the market, achieve profit through cost reduction activities and long-term prosperity.
  10. 10. 11Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN Operating Principles TPS Leadership TPS Toyota’s Philosophy What is Toyota Production System (TPS)?
  11. 11. 12Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN Toyota’s Philosophy Toyota’s Philosophy Operating Principles TPS Leadership TPS Toyota’s Philosophy Eiji Toyoda 1913 -2013 Akio Toyoda 2013 -
  12. 12. 13Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN Guiding Principles at Toyota 1. Always be faithful to your duties, thereby contributing to the company and to the overall good 2. Always be studious and creative, striving to stay ahead of the times 3. Always be practical and avoid frivolousness 4. Always strive to build homelike atmosphere at work that is warm and friendly 5. Always have respect for spiritual matters and remember to be grateful at all times Sakichi Toyoda Founder of Toyota
  13. 13. 14Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN Guiding Principles at Toyota 1. Honor the language and spirit of the law of every nation and undertake open and fair business activities to be a good corporate citizen of the world. 2. Respect the culture and customs of every nation and contribute to economic and social development through corporate activities in their respective communities. 3. Dedicate our business to providing clean and safe products and to enhancing the quality of life everywhere through all of our activities. 4. Create and develop advanced technologies and provide outstanding products and services that fulfill the needs of customers worldwide. 5. Foster a corporate culture that enhances both individual creativity and the value of teamwork, while honoring mutual trust and respect between labor and management. 6. Pursue growth through harmony with the global community via innovative management. 7. Work with business partners in research and manufacture to achieve stable, long- term growth and mutual benefits, while keeping ourselves open to new partnerships. Eiji Toyoda 1913 - 2013
  14. 14. 15Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN Toyota’s Philosophy - People  The Toyota Production System (TPS) itself is based on the belief that the company that ignores human respect will not endure  People – a company’s greatest asset is its people. Toyota does as much as possible to take care of the employees, recognizing first and foremost the importance of job security  People enjoy their work when it involves trying out their own ideas, mastering new skills and making visible contributions  Teamwork is a foundation of TPS – all employees are required to participate and to follow rules and principles of TPS  Operators who are the most knowledgeable of any manufacturing operation are people who perform that job daily – their involvement is critical to the success of implementation of TPS  “Good Thinking, Good Product” – employees are expected to contribute to the improvement of their own work. Sakichi Toyoda Founder of Toyota
  15. 15. 16Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN Toyota’s Philosophy - People  We respect our employees and believe that the success of our business is led by each individual’s creativity and good teamwork  We respect and honor the human rights of people involved in our business  Through communication and dialogue with our employees, we build and share the value “Mutual Trust and Mutual Responsibility” and work together for the success of our employees and the company  Management of our company takes leadership in fostering a corporate culture and implementing policies that promote ethical behaviorEiji Toyoda 1913 - 2013
  16. 16. 17Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN Guiding Principles of Toyota Revised April 1997 1. Honor the language and spirit of the law of every nation and undertake open and fair corporate activities to be a good corporate citizen of the world. 2. Respect the culture and customs of every nation and contribute to economic and social development through corporate activities in the communities. 3. Dedicate ourselves to providing clean and safe products and to enhancing the quality of life everywhere through all our activities. 4. Create and develop advanced technologies and provide outstanding products and services that fulfill the needs of customers worldwide. 5. Foster a corporate culture that enhances individual creativity and teamwork value, while honoring mutual trust and respect between employees and management. 6. Pursue growth in harmony with the global community through innovative management. 7. Work with business partners in research and creation to achieve stable, long-term growth and mutual benefits, while keeping ourselves open to new partnerships.
  17. 17. 18Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN
  18. 18. 19Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN
  19. 19. 20Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN
  20. 20. 21Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN
  21. 21. 22Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN
  22. 22. 23Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN
  23. 23. 24Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN
  24. 24. 25Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN Toyota’s Philosophy - Operating Guidelines  Toyota’s goal is to contribute positively to the society and provide for the welfare of our employees through the provision of better cars, at the better prices, for more people.  Produce superior automobiles that are in total balance with Customer’s desires for quality and performance, while at the same time answering other modern-day needs such as resource conservation, clean exhaust emissions and safety.  Customers are the reason for existence and they must always receive a perfect product or service  Assure high quality by building it at each process. Defects are never passed on to following process.  Improvement is always possible and necessary. Continuously improve every aspect of the system through Kaizen. Any existing process can be improved - no ifs, buts or maybes Akio Toyoda 2013 -
  25. 25. 26Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN TPS Manufacturing Philosophies  Expected cost reductions and process improvements can be achieved only, by implementing, supporting and maintaining following TPS Manufacturing methodologies and principles:  Every customer-supplier connection must be direct and there must be a clear-cut way to send requests and receive responses.  All production lines must be balanced and operating to the Takt time  The pathway for every product and service must be simple and direct.  All our process must flow without interruption  All inventory buffers are wasteful and need to be eliminated.
  26. 26. 27Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN TPS Manufacturing Philosophies  All inventory levels will be determined based on the frequency of deliveries, delivery lead times and consumption rates.  All inventories will be stored in centralized Supermarkets.  Production Schedule will be issued only to a single operation (pacemaker), all preceding operation will work to the Pull System signal.  All production must be scheduled in the smallest logical lot sizes.  Daily schedule attainment is mandatory. Manufacturing will not overproduce, under-produce or produce too soon.  All deliveries of parts and components, internal and external, will be conducted frequently and in smallest possible lots.
  27. 27. 28Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN TPS Manufacturing Philosophies  All production down time due to parts shortage must be eliminated.  All Waste is not acceptable and must be eliminated  Our Set-up and Changeover processes must be minimized – SMED  All work shall be highly specified as to content, sequence, timing, and outcome and be defined in terms of Standardized Work.  All equipment and work cells will be designed to support continuous flow processing  Manufacturing equipment will be maintained properly and repaired swiftly  All vital information required to make shop floor decisions will be visually displayed for anybody to see and to understand.
  28. 28. 29Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN How do we translate these philosophies?  By definition: Lean is a logical collection of philosophies, operating principles, methodologies and tools, which will lead any Company to greater cost reductions and efficiencies improvements.  How are Toyota's philosophies, policies and practices translated in your Company?  What is essential?  What is difficult?  What is misunderstood?  What are the major issues?  What are the corporate policies needed to support philosophies of Lean?
  29. 29. 30Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN Operating Principles Operating Principles Operating Principles TPS Leadership TPS Toyota’s Philosophy PeopleEnterprise Tools and Methods
  30. 30. 31Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN TPS Operating Principles - Business Enterprise
  31. 31. 32Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN TPS Operating Principles - Business Principle: Base your management decisions on a long term philosophy, even at the expense of short-term financial goals  Have a philosophical sense of purpose that supersedes any short-term decision making. Work, grow and align the whole organisation toward a common purpose that is bigger than making money.  Understand your place in the history of the company and work to bring the company to next level. Your philosophical mission is the foundation for the other principles.  Generate value of the customer, society and the economy - it is your starting point. Evaluate every function in the company in terms of ability to achieve this.  Be responsible. Strive to decide your own fate. Act with self reliance and trust in your own abilities. Accept responsibility for your own conduct and maintain improve the skills that enable you to produce added value. Enterprise
  32. 32. 33Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN TPS Operating Principles - Business Toyota Motor Company Toyota Production System, p.1 Enterprise
  33. 33. 34Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN TPS Operating Principles - Business Principle: Constantly shorten the time it takes to convert Customer orders into deliveries.  Lead time is defined as total time required to manufacture an item, including order preparation time, queue time, setup time, run time, move time, inspection time, and put-away time.  An effort should be made to continuously reduce time from release of an order to production and shipment. For make-to-stock products, it is the time taken from the release of an order to production and receipt into finished goods inventory.  Excess inventory presents a great deal of waste, not to mention quality issues (spoilage), storage requirements, investment of funds, limiting cash flow, among others. Reducing inventory will decrease your lead-time.  Careful consideration of cost, replenishment lead-times, and space requirements play an important role in determining reduced inventory levels. The order process is often changed and more inventory is repositioned at “points of use.” Enterprise
  34. 34. 35Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN TPS Operating Principles - Business Enterprise
  35. 35. 36Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN Principle: Add value to your organization by developing your people and partners  Grow leaders who thoroughly understands the work, live philosophy and teach it to others. Grow leaders within, rather than buying them from outside the organisation.  Do not view the leader's job as simply accomplishing tasks and having good people skills. Leaders must be role models for the company's philosophy and the way of doing business.  A leader must understand the daily work in great detail so that he or she can be a best teacher of your company's philosophy.  Have respect for your partners and suppliers and treat them as an extension of your business.  Challenge your outside business partners to grow and develop. It shows that you value them. Set challenging targets and assists your partners in achieving them. TPS Operating Principles - Business Enterprise
  36. 36. 37Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN People TPS Operating Principles - People
  37. 37. 38Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN Principle: Develop exceptional people and teams who follow your company's philosophy  Create a strange, stable culture in which company values and beliefs are widely shared and lived out over a period of many years.  Train exceptional individuals and teams to work within the corporate philosophy to achieve exceptional results. Work hard to reinforce the culture continually.  Use Cross functional teams to improve quality and productivity and enhance flow by solving difficult technical problems.  Empowerment occurs only when people use the company's tools to improve company.  Make an ongoing effort to teach individuals how to work together as teams together toward common goals. Team work is something that has to be learned. People TPS Operating Principles - People
  38. 38. 39Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN People TPS Operating Principles - People
  39. 39. 40Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN Principle: Continuously drive root cause problems solving activities  Go and see for yourself to thoroughly understand the situation.  Solve problems and improve processes by going to the source and personally observing and verifying data rather than theorizing on the basis of what other people or the computer screen tell you.  Think and speak based on personally verified data.  Even high-level managers and executives should go and see things for themselves, so they will have more than a superficial understanding of the situation.  Any improvement must be made in accordance with the scientific method, under the guidance of a teacher, at the lowest possible level in the organization  A manager’s or supervisor’s role consists of leading problem solving activities in a multi-skilled, cross-functional team environment People TPS Operating Principles - People
  40. 40. 41Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN People TPS Operating Principles - People
  41. 41. 42Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN Principle: Make decision slowly by consensus, thoroughly considering all options; implement decisions rapidly. Practice PDCA.  Do not pick a single direction and go down that one path until you have thoroughly considered alternatives.  Nemawashi is the process of discussing problems and potential solutions with all of those affected, to collect their ideas and get agreement on a path forward. This consensus process, though time - consuming, helps broaden the search for solutions, and once a decision is made, the stage is set for rapid implementation.  PDCA is a systematic four-step management method used in business for the control and continuous improvement of processes and products.  PDCA provides a systematic approach to achieving continuous improvement.  It is a great management and communication tool People TPS Operating Principles - People
  42. 42. 43Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN People TPS Operating Principles - People
  43. 43. 44Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN TPS Operating Principles - People Principles: Continually improve standard processes and procedures in order to ensure maximum quality, improve efficiency and eliminate waste  Continuous improvement process (CI), is an ongoing effort to improve products, services, or processes.  Continuous Improvement efforts seek "incremental" improvement over time or "breakthrough" improvement all at once.  Value added processes are constantly evaluated and improved and non-value added process and Waste are minimized or eliminated.  Continuous Improvement is a gradual never-ending process which is focussed on increasing the effectiveness and/or efficiency of an organisation.  Continuous Improvement is not limited to quality initiatives. Put simply - it means ‘getting better all the time’. People
  44. 44. 45Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN People TPS Operating Principles - People
  45. 45. 46Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN Principle: Build a culture of stopping to fix a problem and to get quality right at the first time  Quality of the customer drives your value proposition  Use all the modern quality assurance methods available  Build into your equipment the capability of detecting problems and stopping itself. Develop a visual system to alert team or project leaders that a machine or process needs assistance. Jidoka (machines with human intelligence) is the foundation for "building in" quality.  Build into your organisation support systems to quickly solve the problems and put in place countermeasures.  Build into your culture the philosophy of stopping or slowing down to get quality right the first time to enhance productivity in the long run. People TPS Operating Principles - People
  46. 46. 47Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN TPS Operating Principles – Tools and Methodologies Tools and Methods
  47. 47. 48Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN TPS Operating Principles – Tools and Methods Principle: Constantly strive for absolute elimination of waste, overburden and unevenness in all areas.  Meaningful Work consists of:  Value Added Work - operations which increase a value of a product from the Customer’s point of view  Non-Value Added Work – Incidental Work. Work that does not have any particular value, but it has a cost.  The higher the value-added operation in your completed work, the higher the level of production efficiency will be.  Waste (Muda) - is NOT work. Waste are activities, motions, behaviors or actions that are not part of the actual work (non essential activities).  Two major contributors to Waste:  Unevenness - fluctuating schedules, planning and production quantities  Overload - machine or employee pushed beyond natural limits of their capacity Tools and Methods
  48. 48. 49Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN TPS Operating Principles – Tools and Methods Tools and Methods
  49. 49. 50Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN Principle: Standardize all processes and procedures to ensure a safe method of operation and a consistent approach to Quality.  Use stable, repeatable methods everywhere to maintain the predictability, regular timing and regular output of your processes. It is the foundation for the flow and pull.  Capture the accumulated learning about a process up to a point in time by standardizing today's best practices.  Standardization is a foundation for continuous improvements and employee empowerment  Allow creative and individual expression to improve upon the standard; then incorporate it into the new standard so that when a person moves on you can hand off the learning to the next person. TPS Operating Principles – Tools and Methods Tools and Methods
  50. 50. 51Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN TPS Operating Principles – Tools and Methods Tools and Methods
  51. 51. 52Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN Principle: Create continuous flow of production to bring problems to the surface  Redesign work processes to achieve high value-added, continuous flow of information, product, materials and people.  Strive to cut back to zero the amount of the time that any work project is sitting idle or waiting for someone to work on it.  Create flow to move material and information fast as well as to link processes and people together so that problems surface right way.  Make flow evident throughout your organizational culture. It is the key to a true continuous improvement process and to developing people. TPS Operating Principles – Tools and Methods Tools and Methods
  52. 52. 53Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN TPS Operating Principles – Tools and Methods Tools and Methods
  53. 53. 54Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN Principle: Use Pull system to avoid overproduction and excess inventories  If you cannot flow production, information, material and people - Pull  Provide your downline customers in production process with what they want, when they want it and in the amount they want it.  Material replenishment initiated by consumption in the basic principle of JIT Just- in-Time.  Minimize your work in process and warehousing of inventory by stocking small amounts of each product and frequently restocking based on what the customer actually takes away.  Be responsive to the day-by-day shifts in customer demand rather than relying on computer schedules and systems to track wasteful inventory. TPS Operating Principles – Tools and Methods Tools and Methods
  54. 54. 55Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN TPS Operating Principles – Tools and Methods Tools and Methods
  55. 55. 56Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN Principle: Level out the workload – avoid unevenness, un-leveled workload (Mura)  Eliminating waste is just one-third of the equation for making lean successful. Eliminating overburden to people, equipment and eliminating unevenness in the production schedule is just as important - yet generally not understood at companies attempting to implement lean principles.  Work to level out the workload of all manufacturing and service processes as an alternative to the start/stop approach of working on projects in batches that is typical at most companies. TPS Operating Principles – Tools and Methods Tools and Methods
  56. 56. 57Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN TPS Operating Principles – Tools and Methods Tools and Methods
  57. 57. 58Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN Principle: Use Visual Management and Controls so no problems are hidden  Use simple visual indicators to help people determine immediately whether they are in a normal (standard) condition or deviating from it (abnormal condition).  Is this situation normal or abnormal? Is this good or bad? Do I need to take action?  Design a simple system where any abnormality is identified immediately  process/operation – are all procedures being followed?  equipment/machinery – are they producing good parts?  expected levels of performance / inventory  Purpose - to delegate the decision making process to the lowest level of the organization  implement audio-visual controls  eliminate dependency on a few “decision makers” TPS Operating Principles – Tools and Methods Tools and Methods
  58. 58. 59Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN TPS Operating Principles – Tools and Methods Tools and Methods
  59. 59. 60Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN Principle: Use only reliable, thoroughly tested technology that servers your people and process  Use technology to support people not to replace people. Often it is best to work out process manually before adding technology to support the people.  New technology is often unreliable and difficult to standardize and therefore endangers "flow". A proven process that works generally takes precedence over new and untested technology.  Conduct actual tests before adopting new technology in business processes, manufacturing systems or products.  Reject or modify technologies that conflict with your culture or that might disrupt stability, reliability and predictability.  Nevertheless encourage your people to consider new technologies when looking into new approaches to work. Quickly implement a thoroughly considered technology if it has been proven in trials and it can improve flow in your processes. TPS Operating Principles – Tools and Methods Tools and Methods
  60. 60. 61Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN Stability GOAL: Highest Quality, Lowest Cost, Shortest Lead Time 1. Stable Manufacturing Processes 2. 100% Quality Parts Heijunka Standardized Work Kaizen Just-in-Time Jidoka Stop the line and fix the Problem Separate man’s work from machine’s work Continuous Flow Takt Time Pull System The Toyota House Toyota Production System (TPS) 1987
  61. 61. 62Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN Leadership’s Role in TPS TPS Leadership Operating Principles TPS Leadership TPS Toyota’s Philosophy
  62. 62. 63Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN Leadership Style at Toyota  Organizational structure based on a Military model  Manager, Group Leader, Team Leader, Team Members  Toyota Production System (TPS) rules  Managers do not tell people what to do! – managers expect employees to perform their jobs according to Standardized Work  Managers job is to deal with and resolve abnormal situations  Process  People  How is this accomplished? Operating philosophies:  “The nail that sticks out get hammered in”  “Carrot” and “Stick” approach - military model  “Golden Handcuffs”  Be creative, but follow the rules
  63. 63. 64Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN Leadership Style at Toyota  Your initial perception is – this is a very rigid and well disciplined environment  Nobody is late for work  People do what they were trained to do  Things are working well and nobody is in charge  Roles and responsibilities for all levels very clearly defined  Best practices for all (standardized work), goals , targets and objectives well defined and known to all  Everybody knows what to do and they do it on regular basis  Everybody performs their duties (most of the time)
  64. 64. 65Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN TPS Leadership Style  TPS Leaders have to be quick studies, nimble, and trusting of their employees  Having deep skills and technological experience is not enough  Becoming a Leader, at any level, requires the development and utilization of strong people skills  TPS Leadership is exclusively about people – you do not lead machines or processes, you lead people
  65. 65. 66Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN Eiji Toyoda on Leadership “The people at the top are just flag-wavers. It is pure MUDA to wave your flag and have no one follow you. Waving that flag in a way that makes people fall in line behind you is what is important.” Eiji Toyoda Eiji Toyoda 1913 -2013
  66. 66. 67Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN Chairman of Toyota Motor Corp. and former President of Toyota Motor Manufacturing, KY and Toyota Motor Corp. Toyota’s Chairman Fujio Cho Three Keys to Lean Leadership  Go See  “Senior Management must spend time on the front lines”  Ask Why  “Use the “Why” techinques daily.”  Show Respect  “Respect your people.”
  67. 67. 68Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN Chairman of Toyota Motor Corp. and former President of Toyota Motor Manufacturing, KY and Toyota Motor Corp. Toyota’s Chairman Fujio Cho “Many good companies have respect for individuals and practice Kaizen and other TPS tools. But what is important is having all elements together as a management system. It must be practiced every day in a very consistent matter – not is spurs – in a concrete way on the shop floor.”
  68. 68. 69Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN Toyota’s Philosophy – Manager’s Role  In a true TPS environment decision making process should be made at the lowest possible level of the organization.  Simple, effective solutions are the most effective  A manager’s or supervisor’s role consists of leading problem solving activities in a multi-skilled, cross-functional team environment  Managers role is to make sure that for everything that we do there is a well defined standard process  Continuous Improvement (Kaizen) activities are management responsibilities.
  69. 69. 70Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN Problem Solving process  TPS creates a community of scientists and analysts  Toyota uses rigorous problem solving process that requires a detailed assessment of the current state of affairs and a plan for improvement  With anything less than such a scientific rigor, change would amount to little more than random trial and error – a blindfolded walk through life  This process actually stimulates operators and managers to engage in the kind experimentation that is widely recognized as a starting point of Continuous Improvement
  70. 70. 71Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN Continuous Improvement must be Leadership driven  Continuous Improvement is a process of discovering and eliminating problems – elimination of Waste  There are two types of CI activities:  methods improvements and  equipment improvements  Leaders must be skillful in identifying these problems and leading Continuous Improvement activities to eliminating them  Production Leaders (Supervisors) must become experts in Standardized Work  They should be able to analyze, study, and simplify work methods. It is a starting point for making improvements  Implementation of Toyota Production System must be taken seriously and supported by all levels of the organization - Implementation process is not optional.
  71. 71. 72Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN Continuous Improvement activities  Toyota does not expect their employees to initiate any CI activities or to learn how to conduct improvements strictly from their personal experience  Toyota explicitly teaches people how to improve  Toyota provides training and creates environment to foster (to encourage) Continuous Improvement activities:  Quality circles  Suggestion program  Daily problem “Auctions”  Kaizen events  Etc …
  72. 72. 73Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN Managing at Toyota  Managers in Toyota never say Yes easily; they rarely say No - The often say Maybe.  In traditional companies managers are forced to explain “why” to their subordinates when saying to them – “stop doing this or no, you can’t do that.”  At Toyota, the burden of proof is always on the subordinate, who must justify why an action is necessary  At Toyota manager leads in a very different way:  by example  by being knowledgeable  by getting into the messy details  by questioning  by coaching  by building robust, sensible systems and processes that cascade responsibility
  73. 73. 74Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN Manager’s Role at Toyota  Managers role is to make sure that for everything that we do there is a well defined process  If something goes wrong, the first line of questions that Manager must ask are:  What went wrong?  What is acceptable and what is not acceptable?  Did we have a process for this particular situation?  Did we follow the process?  Was there a problem with the process or the problem occurred because we did not follow the process they we should?
  74. 74. 75Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN How Toyota’s Workers Learn the Rules  Toyota’s managers do not tell workers and supervisors specifically how to do their work. They coach them.  Rather, they use a teaching and learning approach that allows their workers to discover the rules as a consequence of solving problems  The manager teaching a person, will come to the work site and, while the person is doing his or her job, ask a series of questions:  Show me how do you do this work?  Show me how do you know you are doing this work correctly?  How do you know that the outcome is free of defects? Show me.  Show me what do you do if you have a problem?
  75. 75. 76Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN Learning about Toyota’s Management Style  Responsibility and Authority  In a traditional company:  responsibility is never clear  and there is endless fighting over escaping it  At Toyota:  responsibility is always clear  and there is endless fighting over increasing it  The Chief Engineer says: “I have no authority.”  Everyone else says: “The Chief Engineer is the most powerful person in the company.”
  76. 76. 77Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN TPS Tools and Methodologies TPS Leadership TPS Toyota’s Philosophy What is Toyota Production System (TPS)?
  77. 77. 78Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN Toyota Production System (TPS) We never asked Toyota how did they build and manage their house of TPS?
  78. 78. 79Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN What is Lean Transformation? Lean Transformation of Tools and Methodologies Lean Transformation of how we Think and Manage Lean does not work for us
  79. 79. 80Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN Knowledge and Skills To know, to understand the meaning correctly and to be able to teach Lean Knowledge Kanban, Pull system, Jidoka, Supermarket, TPM, SMED, JIT, Kaizen, STW, 5S, WCT, VSM, Gemba, Takt Time, etc … I know this! Lean Skills Be able to solve problems and advance the organization by using proper Lean Knowledge Use Lean Knowledge to motivate people, achieve results, reduce costs, improve the operation and address business needs Can you Play a Violin?
  80. 80. 81Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN How to Implement Lean ? I know Lean Engineering driven Hobby driven Knowledge Driven Kanban Leveled schedule Supermarket SMED PullTPMHeijunka Jidoka VSM Business NEEDS driven 1. USE KPIs to understand your Current Status 2. Set goals and objectives 3. Start solving problems 4. Check progress and measure results B A True North “So what ?“ 5 S PokaYoke
  81. 81. 82Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN How to Implement Lean ? I know Lean Engineering driven Hobby driven Knowledge Driven Kanban Leveled schedule Supermarket SMED PullTPMHeijunka Jidoka VSM Business NEEDS driven 1. USE KPIs to understand your Current Status 2. Set goals and objectives 3. Start solving problems 4. Check progress and measure results B A True North “So what ?“ 5 S PokaYoke
  82. 82. 83Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN Create a “Learning Organization” 2016
  83. 83. 84Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN TBP – Toyota Business Practices 2. PPS (Practical Problem Solving) 1. Hoshin Kanri (True North – Management Direction) 3. OJT (On-the-Job-Training) 4. Rapid PDCA (Plan-Do-Check-Act) Toyota Way 2001
  84. 84. 85Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN TBP - Create a “Learning Organization” 1. Management directed initiatives – True North 2. Utilizing Problem Solving Methodology 3. Sustained through On-the-Job-Training 4. Achieved using rapid PDCA by all associates 2. PPS (Practical Problem Solving) 1. Hoshin Kanri (True North – Management Direction) 3. OJT (On-the-Job-Training) 4. Rapid PDCA (Plan-Do-Check-Act) Toyota Way 2001
  85. 85. 86Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN The Toyota Way Continuous Improvement Respect for People Challenge Kaizen Genchi Gembutsu Respect Teamwork Toyota Way 2001
  86. 86. 87Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN TBP – Toyota Business Practices TBP was developed to practice the Toyota Way in everyday business around the world Toyota Business Practices Toyota Problem Solving TOYOTA WAY Concrete Actions and Processes Drive and Dedication Toyota Way 2001
  87. 87. 88Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN TBP – Concrete Actions and Processes 1. Clarify the Problem 2. Break Down the Problem 3. Set a Target 4. Analyze the Root Cause 5. Develop Countermeasures 6. See Countermeasures Through 7. Monitor both Results and Progress 8. Standardize Successful Process P C D A Toyota Business Practices Toyota Problem Solving TOYOTA WAY
  88. 88. 89Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN • Customer First • Always Confirm the Purpose of Your Work • Ownership and Responsibility • Visualization • Judgment Based on Facts • Think and Act Persistently • Speedy Action in a Timely Manner • Follow Each Person with Sincerity and Commitment • Thorough Communication • Involve All Stakeholders TBP – Drive and Dedication Toyota Business Practices Toyota Problem Solving TOYOTA WAY
  89. 89. 90Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN Toyota Way - Drive and Dedication  Customer First  Always think and act for the benefit of customers, and place their interests ahead of all others.  Subsequent processes are also considered our customers.  Always Confirm the Purpose of Your Work  Constantly question the purpose of your work seeking your own answer.  Do not lose sight of the overall goal and purpose when focused upon a specific task.  Ownership and Responsibility  Be aware that you are the main person who is responsible for your work.  Recognize the mission, value and pride in your work, and envision your goal. Toyota Business Practices Toyota Problem Solving TOYOTA WAY Toyota Way 2001
  90. 90. 91Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN Toyota Way - Drive and Dedication  Visualization  Promote visualization and clarify problems for everyone to understand.  Information should be shared on a timely basis for the benefit of all.  Judgment Based on Facts  Without prejudice or preconception, investigate all the facts: go and see the situation as it truly is.  Think and Act Persistently  Think deeply and commit to the completion of a task with a strong belief in not giving up.  Speedy Action in a Timely Manner  Be adaptable to customers’ needs, and fulfill them quickly.  If necessary, use temporary measures until you can implement countermeasures. Toyota Business Practices Toyota Problem Solving TOYOTA WAY Toyota Way 2001
  91. 91. 92Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN Toyota Way - Drive and Dedication  Follow Each Process with Sincerity and Commitment  Be committed to follow the process without taking shortcuts. Listen to others’ opinions with an open mind. Possess a sense of responsibility towards your own actions.  Thorough Communication  Thoroughly and sincerely communicate with stakeholders until they gain deep understanding.  Involve All Stakeholders  Involve relevant members and partners to increase knowledge and wisdom as well as to maximize the efficiency and output of the group. Toyota Business Practices Toyota Problem Solving TOYOTA WAY Toyota Way 2001
  92. 92. 93Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN TBP – Toyota Business Practices 1. Clarify the Problem 2. Break Down the Problem 3. Set a Target 4. Analyze the Root Cause 5. Develop Countermeasures 6. See Countermeasures Through 7. Monitor both Results and Progress 8. Standardize Successful Process P C D A • Customer First • Always Confirm the Purpose of Your Work • Ownership and Responsibility • Visualization • Judgment Based on Facts • Think and Act Persistently • Speedy Action in a Timely Manner • Follow Each Person with Sincerity and Commitment • Thorough Communication • Involve All Stakeholders Drive and DedicationConcrete Actions and Processes Toyota Business Practices Toyota Problem Solving TOYOTA WAY
  93. 93. 94Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN Changing the World. One Transformation at a time This presentation is an intellectual property of W3 Group Canada Inc. No parts of this document can be copied or reproduced without written permission from: Marek Piatkowski W3 Group Canada Inc. iPhone: 416-235-2631 Cell: 248-207-0416 Marek.Piatkowski@rogers.com http://twi-network.com Thinkingwin, Win, WIN
  94. 94. 95Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN Presentations in this Workshop 1. Log in to: www.slideshare.net 2. Type in my name in search area: Marek Piatkowski 3. Select a presentation you want to see 4. Learn and Enjoy
  95. 95. 96Marek.Piatkowski@Rogers.com What is Toyota Production System Introduction Thinkingwin, Win, WIN Introduction to TPS and Lean The End

×