tps

1. 1
LEAN MANUFACTURING
(TOYOTA PRODUCTION SYSTEM)
Prasanna M DAE.,BE,ME
MADURAI TAMILNADU
INDIA

2. LEAN MANUFACTURING
“Lean Manufacturing, also called Lean Production,
Lean Production can be defined as an integrated set of activities designed to
achieve high-volume production using minimal inventories (raw materials,
work in process, and finished goods)
which shortens the time line between the customer order and the product
shipment by eliminating waste.
Customer
Order
Waste Product
Shipment
Time
Customer
Order
Product
Shipment
Time (Shorter)
Waste
Lean Manufacturing

3. LEAN MANUFACTURING
Lean is about understanding what is important to the customer
The main benefits of this are
Lower production costs
Increased output
shorter production lead times
Customer
Order
Waste Product
Shipment
Time
Customer
Order
Product
Shipment
Time (Shorter)
Business as Usual
Waste
Lean Manufacturing

4. Redesign of this job to eliminate the need to
walk doubled its productivity.

5. Elimination of waste
Waste can be defined as the Toyota president fujio cho, “ is anything other than
minimum amount of equipment's, materials, workers are absolutely essential
to production
Different types of waste is to be eliminated from the value strem
Waste of waiting
time
Waste of
Processing time
Waste of counting
parts

6. Waste from
overproduction
Transportion
Waste
Inventory waste
Waste from
defects
Waste for
searching tools Wastage of
machine failure

7. Toyoto production system
TPS was developed to improve the quality and the productivity
Based on two categories
1. Elimination for waste
2. Respect for people

8. Elimination of waste
1. Focussed factory networks
2. Group Technology
3. Quality at the source
4. JIT production
5. Uniform plant loading
6. Kanban Approach
7. Minimized setup times

9. Focused factory networks

10.  Lot of unnecessary material Movement
 Flow lines (Production) are going back
and forth
Departmental specialization Group Technology Manufacturing Cell
Plant layout
 Reduced the material Movement
 Improve the Flow lines (Production)
Group Technology

11. Quality at the source
Self inspection

12. Jit (Just in Time)
 Producing the Quantity of units that is needed
 Producing them on date/time required
 Suppliers delivered to the exact quantity demanded at the scheduled time
& date
JIT
(JUST-IN-
TIME)
JIT involves the set of activities
designed to achieve high volume
of Production using Minimum
Inventories

13. Purchasing material Process Products Sell Products
Purchasing material Process Products Sell Products
Raw Material Inventory Finished Inventory
Traditional Approach
Just In Time (JIT) Approach

14. Just In Time (JIT) Approach
 Producing the Quantity of units that is needed
 Producing them on date/time required
 Suppliers delivered to the exact quantity demanded at the scheduled time & date

15. Uniform Plant Loading
 Smoothening the production flow to dampen the reaction waves that
normally occurs in response to schedule variations is called UPL
 When a change is made in a final assembly, the change are magnified
throughout the line and the supply chain. The only way to eliminate the
problem is to make adjustments as small as possible by setting a firm
monthly production plan for which the output rate is frozen
 Toyota found they could do this by building the same mix of products
everyday in the small quantities. Thus, they always have a total mix
available to respond to variations in demand.

16. Push and Pull method of Work Flow
Push Method: A method in which production of the item begins in advance of
customer needs.
Example: A buffet where food is prepared in advance.
Pull Method: A method in which customer demand activates production of the
service or item.
Example: A restaurant where food is only prepared when orders are
placed.
Lean systems use the pull method of work flow.

17. KANBAN Approach

18. KANBAN Approach

19. KANBAN Approach

20. KANBAN Approach

21. KANBAN Approach

22. KANBAN Approach

23. KANBAN Approach

24. Kanban system rules
1.1. Each container must have a card
2.2. Assembly always withdraws from fabrication (pull system)
3.3. Containers cannot be moved without a kanban
4.4. Containers should contain the same number of parts
5.5. Only good parts are passed along
6.6. Production should not exceed authorization

25. Minimized the setup times
 Since small lot sizes are normal, machine must be quickly setup to
produced the mixed models on the line.
 Widely Cited example from the late 1970s, Toyota teams of press operators
producing car hoods and fenders where able to change an 800ton press in
10min, compared with average of 6hrs of US workers and 4hrs for German
workers
 Now such speeds is common in most US auto plants
 To achieve such setup time reduction setups are divided in to
 Internal activities ( setup must be done while the
machine is stop)
 External activities (Setups can be done while machine is
running)

26. Respect for People
 Level payrolls
 Co operative employee unions
 Subcontarctor network

27. Toyoto Production System – Four Rules
1. All work shall be highly specified as to content, sequence, timing, and
outcome
2. Every customer-supplier connection must be direct, and there must be an
unambiguous yes-or-no way to send requests and receive responses
3. The pathway for every product and service must be simple and direct
4. 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