A Fast Look At The Toyota Production System - TPS
Properly, sure, there's some secret sauce. Nevertheless it isn't so secret - it is truly fairly well documented. It's called the Toyota Manufacturing System, and I might like to explain a bit about it today.
TPS is a completely built-in socio-technical system comprising of it's management principles, firm philosophy, and manufacturing practices. Initially often called "just in time" (or JIT), it draws upon the work of the founders of Toyota, his son, and an engineer - which in turn drew their inspiration from Henry Ford. The Toyota workers came to America to observe the Ford manufacturing methods, but were decidedly unimpressed with the entire operation. From that experience, and observations of an automatic drink resupply system in the supermarket, they fashioned the ideas of TPS.
The target of TPS is to reduce waste, inconsistency, and overburden. These are embodies within the Japanese terms muda, mura, and muri. The process ought to deliver the required outcomes easily - with out inconsistencies; while being as flexible as necessary without overburdening the lean six sigma green belt certification workers, which might end in waste.
What is waste as addressed by TPS? 7 varieties have been recognized:
Movement (of man or machine)
Ready (of man or machine)
Stock (uncooked materials)
Correction (rework and scrap)
The bodily value of correcting defective products or disposing of them is apparent, but the remaining may have explaining. Movement waste might refer to further actions required on the a part of the meeting line worker who should physically carry gadgets from one machine to a different - which might be reduced by connecting the machines. Waiting waste refers to the time when one machine lies unused, because it is nonetheless "waiting" for an additional course of in the production line to complete - you'll be able to't put the lights on the automotive till the paint has dried, for instance. Wastage of raw supplies can occur because the design of the machine is such that it requires 1m squared of metal to cut a single 50cm squared form - with correct designing, these might combined into 1 larger sheet with less waste cut.