http://www.toyota-global.com/company/vision_philosophy/toyota_production_system/
Accessed on 23 August 2013
This explanation by Toyota Globla is very clear.
Toyota Production System is a production system which is steeped in the philosophy of "the complete elimination of all waste" imbuing all aspects of production in pursuit of the most efficient methods.
This production control system has been established based on many years of continuous improvements, with the objective of "making the vehicles ordered by customers in the quickest and most efficient way, in order to deliver the vehicles as quickly as possible."
The Toyota Production System (TPS) was established based on two concepts: The first is called "jidoka" (which can be loosely translated as "automation with a human touch") which means that when a problem occurs, the equipment stops immediately, preventing defective products from being produced; The second is the concept of "Just-in-Time," in which each process produces only what is needed by the next process in a continuous flow.
-Quality must be built in during the manufacturing process!-
If equipment malfunction or a defective part is discovered, the affected machine automatically stops, and operators cease production and correct the problem.
For the Just-in-Time system to function, all of the parts that are made and supplied must meet predetermined quality standards. This is achieved through jidoka.
Jidoka means that a machine safely stops when the normal processing is completed. It also means that, should a quality / equipment problem arise, the machine detects the problem on its own and stops, preventing defective products from being produced. As a result, only products satisfying quality standards will be passed on to the following processes on the production line.
Since a machine automatically stops when processing is completed or when a problem arises and is communicated via the "andon" (problem display board), operators can confidently continue performing work at another machine, as well as easily identify the problem's cause to prevent its recurrence. This means that each operator can be in charge of many machines, resulting in higher productivity, while continuous improvements lead to greater processing capacity.
- Making only "what is needed, when it is needed, and in the amount needed!"
Producing quality products efficiently through the complete elimination of waste, inconsistencies, and unreasonable requirements on the production line.
In order to deliver a vehicle ordered by a customer as quickly as possible, the vehicle is efficiently built within the shortest possible period of time by adhering to the following:
When a vehicle order is received, a production instruction must be issued to the beginning of the vehicle production line as soon as possible.
The assembly line must be stocked with required number of all needed parts so that any type of ordered vehicle can be assembled.
The assembly line must replace the parts used by retrieving the same number of parts from the parts-producing process (the preceding process).
The preceding process must be stocked with small numbers of all types of parts and produce only the numbers of parts that were retrieved by an operator from the next process.
Jidoka - Even machines do not produce defective parts. This means, human operator will not produce a defective part and pass it on to the next stage.
JIT - Flexible machines with very small set up times
Accessed on 23 August 2013
This explanation by Toyota Globla is very clear.
Toyota Production System is a production system which is steeped in the philosophy of "the complete elimination of all waste" imbuing all aspects of production in pursuit of the most efficient methods.
This production control system has been established based on many years of continuous improvements, with the objective of "making the vehicles ordered by customers in the quickest and most efficient way, in order to deliver the vehicles as quickly as possible."
The Toyota Production System (TPS) was established based on two concepts: The first is called "jidoka" (which can be loosely translated as "automation with a human touch") which means that when a problem occurs, the equipment stops immediately, preventing defective products from being produced; The second is the concept of "Just-in-Time," in which each process produces only what is needed by the next process in a continuous flow.
Jidoka
— Highlighting/visualization of problems —-Quality must be built in during the manufacturing process!-
If equipment malfunction or a defective part is discovered, the affected machine automatically stops, and operators cease production and correct the problem.
For the Just-in-Time system to function, all of the parts that are made and supplied must meet predetermined quality standards. This is achieved through jidoka.
Jidoka means that a machine safely stops when the normal processing is completed. It also means that, should a quality / equipment problem arise, the machine detects the problem on its own and stops, preventing defective products from being produced. As a result, only products satisfying quality standards will be passed on to the following processes on the production line.
Since a machine automatically stops when processing is completed or when a problem arises and is communicated via the "andon" (problem display board), operators can confidently continue performing work at another machine, as well as easily identify the problem's cause to prevent its recurrence. This means that each operator can be in charge of many machines, resulting in higher productivity, while continuous improvements lead to greater processing capacity.
Just-in-Time
— Productivity improvement —- Making only "what is needed, when it is needed, and in the amount needed!"
Producing quality products efficiently through the complete elimination of waste, inconsistencies, and unreasonable requirements on the production line.
In order to deliver a vehicle ordered by a customer as quickly as possible, the vehicle is efficiently built within the shortest possible period of time by adhering to the following:
When a vehicle order is received, a production instruction must be issued to the beginning of the vehicle production line as soon as possible.
The assembly line must be stocked with required number of all needed parts so that any type of ordered vehicle can be assembled.
The assembly line must replace the parts used by retrieving the same number of parts from the parts-producing process (the preceding process).
The preceding process must be stocked with small numbers of all types of parts and produce only the numbers of parts that were retrieved by an operator from the next process.
Jidoka - Even machines do not produce defective parts. This means, human operator will not produce a defective part and pass it on to the next stage.
JIT - Flexible machines with very small set up times
Oct. 11, 1989
TOYOTA INTRODUCES NEW ASSEMBLY LINE CONTROL SYSTEM
Toyota City―TOYOTA MOTOR CORPORATION (TMC) announced today that it has introduced a new production information system on passenger car production lines at the company's Tahara Plant.
The new Assembly Line Control (ALC) system was developed to give Toyota more flexibility in its production system, while maintaining product quality.
With the new system computers are installed on the individual production lines (body, paint, assembly, etc.), allowing local control of operations and greater freedom to respond to line-specific production problems. Coordination of production is achieved through a tagging system that assigns each article or vehicle an antenna, controller, and 8 kilobyte "ID tag" which carries detailed information and instructions needed for the various production processes. By joining each item with its specific production information, the system reduces computer load and allows the complex flow of components and vehicles to be controlled more easily and accurately.
Under the previous system, computerized control of production instructions was carried out centrally by the company's head office. The new ALC system gives individual plants the autonomy to make production control decisions at the production site. Another feature of the ALC is its ability to easily interconnect and utilize different types of equipment, which permits systems to be developed without being restricted to specific computer or equipment manufacturers. The interconnection of information equipment is carried out in the plant network by adopting Manufacturing Automation Protocol, an international standard local area network (LAN) advocated by GM.
The new ALC system is currently in use at the Tahara Plant on the line producing Toyota's two new luxury sedans, the Lexus LS 400 and the Toyota Celsior. Future plans call for the system to be installed at all of Toyota's plants.
Updated on 19.12.2020
First published on 23.8.2013
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