Focus Areas

• History of TPS
• 4 Ps of TPS, House of TPS    
• Guidelines of TPS
• Understanding Value added and Non-Value added ( Muda, Muri, Mura ) activities
• Workplace organization                    
• Visual Management, AndOn
• Value Stream Map
• Quick Change over
• Standard Work 
• Kanban
• Production Levelling ( Heijunka )
• Problem solving Toyota way – Stop and Fix, Problem resolution cycle, Poka-yoke
• Continuous improvement Project management – Toyota A3

Background

Toyota Production System ( TPS ), as we understand from its name, originated in Toyota Motor Corporation, Japan in 50s post 2nd world war, when industries in Japan were challenged to survive and globally competitive. Mr Taichi Ohno ( father of TPS ) , an operational leader in Toyota quickly realized that it has to find an innovative production system to beat mass manufacturing wisdom of American organizations to become globally competitive. Journey toward waste reduction begun, which is revolutionary in manufacturing world.
He created a system based on the principle of single piece flow, opposite to mass manufacturing system. It was difficult to implement as it defies conventional thinking but it brought out huge benefits to the organization to serve multiple customers in shortest possible time and without any defects. To achieve that, it focuses on eliminating wastes, uses minimum resources ( material, man, money, space, time, assets ) with least amount of leftover ( Inventory ). In short, ‘achieve maximum with minimum’. So superior value addition to both customer and producer ensured. The result has been a highly profitable company.
TPS is also known as Lean Manufacturing system and World Class Manufacturing ( WCM ). Toyota’s success story is well documented and accepted globally as the most holistic and efficient system, much more than any other system in the world. Hence the organizations who would like to significantly improve Operational efficiency, Customer service with lowest cost, learning and implementation of Toyota Production system is imperative.

In current situation, macroeconomic environment and cost pressures are posing serious challenges to all major industry sectors. Designing operations in line with TPS principles and guidelines and use of TPS tools and practices can counter these challenges effectively to a great extent.

Keeping this in view, IMTMA is organizing an online training on Principles and Tools of Toyota Production System.

Key Takeaways

• Gain an insight into Toyota Production System. 
• Understand how adoption of TPS can significantly improve Operational efficiency.
• Prepare a roadmap to create Lean Value Stream.
• Learn various TPS Tools and Techniques to be a basic expert.
• Plan a journey toward JIT and Jidoka – 2 key objectives of TPS.
• Use the training materials and various examples as reference for implementation

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