1) The Toyota Production System (TPS) is Toyota's internally developed production system established through improvements over many years. It is known as a "lean manufacturing system". 2) TPS has three basic concepts or "pillars": Just-in-Time, which focuses on producing what is needed when it is needed in the needed amount; Autonomation, which focuses on automatically stopping and notifying abnormalities to separate man and machine work; and Leveling, which focuses on leveling production types and quantities over fixed periods to reduce waste from fluctuations. 3) TPS was developed in response to Toyota's late entry into the automotive market and lack of infrastructure, and aimed to manufacture cars through original techniques

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The Key concept in Toyota Production
System and their own thought
― Building original unified man-machine system ―
Iwaki Production System research Ltd.
Toshiaki Yanagida
QuEST APAC Tokyo BPC
4/15/2015
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2. 2
Introduction
• Welcome to Japan.
• I present about TOYOTA Production System (TPS).
– TPS was production system developed by
TOYOTA and established through long period of
their improvement.
– TPS is famous for the name called “Lean
manufacturing system” and well known in the
world and many people study now.

3. TOYOTA Production System
Mechanism of TPS
・Pull Production
・KANBAN（for Information ）
・Automatic stop mechanism
・Small lot production etc.
three basic concepts
(pillars)
The thought
in the undercurrent of TPS
The background
・the environment
・their spirit
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4. 4
What is TOYOTA Production
System (TPS)
• TPS is the total production system what
TOYOTA made by themselves internally
from TOYOTA establishment (1937).
• There are three basic concepts (pillars) in
TPS.
–Just-in-time
–Autonomation: This word is slightly different
–Leveling from usual Automation.

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Just-in-time
• To make and deliver what is needed, just when it is
needed, and just in the amount needed.
• (Originator) Mr.Kiichiro Toyoda‘s Spirit of foundation.
He is a founder of TOYOTA.
• He got an idea from supermarkets in USA.
• Mechanism
– Pull production system
– Information communication by "KANBAN" etc.

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Autonomation ＜ Jidouka ＞
• Stop and notify abnormalities automatically and
separate man-machine work“. not automation.
• (Originator) Mr. Sakichi Toyoda’s spirit of invention.
He is Mr.Kiichiro‘s father who invented "non-stop shuttle
replacement expression Toyoda automatic loom (type G)".
• "Automation" goes with loss.
• Mechanism
– Automatic stop mechanism against abnormality
– the line stop rule. etc.

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Leveling ＜ Heijunnka ＞
• Leveling the type and quantity of production over
a fixed period of time.
• (Originator) Mr.Taiichi Ouno who is actual TPS originator
and he thought leveling so strong.
• When the production flow will be much fluctuated,
waste should be much bigger．
• Mechanism
– Small lot production.
– Single setup (changeover). etc.

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The background why TPS was born
(the environment)
• TOYOTA was very late departure company in
comparison with an overseas manufacturer.
• The Japanese market size at that time was
one-50th of the United States.
• Almost none of Infrastructure (technics
related company) was maintained.

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The background why TPS was born
(their spirit)
• They didn't want to follow European and
American style.
• They wanted to manufacture cars by their
original techniques.

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The thought in the undercurrent of TPS
• A person works willingly by oneself.
So we shall utilize these persons.
• The quantity to sell goods is limited.
So we shall work with the limited quantity.
• The quantity involves loss.
So we shall think how to stop loss rather
than quantity at first.

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Way of thinking of quality
improvement in TPS
• It's made in the flow.
• Setting and obeying of standard work (work
procedure, cycle time and the number of holdings).
• Pursuit of root cause ( 5 Why), measure and
level development.

12. TOYOTA Production System
Mechanism of TPS
・Pull Production
・KANBAN（for Information ）
・Automatic stop mechanism
・Small lot production etc.
three basic concepts (pillars)
・Just-in-time
・Autonomation ＜Jidouka＞
・Leveling ＜Heijunnka＞
The thought in the undercurrent of TPS
・A person works willingly by oneself.
・The quantity to sell of goods is limited.
・The quantity involves loss.
The background
・the environment
・their spirit
Thorough
Exclusion
of
Waste
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Future TPS
• TPS is a production system suitable for multi-
objective production.
• There is accumulation of the technology, know-
how and tools for the past 70 years.
⇒ TPS will grow in future and will spread.
The important thing is that not only
“ the structure of production system ”
but also “ factory culture and their mind ”
is improved together.

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My Expectation
• "Exclusion of waste of the material and
the energy of the person" is also
important thing for the continuation of
the global environment.
• I hope that TPS is useful in the various
parts of the worlds.
Thank you.