Toyota Production system Flashcards
What year was the manufacturing boom?
1950-1960
When was the manufacturing bust?
1970-80
What caused the manufacturing bust?
- American firms became lax
- As American goods were the envy of the world, firms could
largely dictate the quality specifications of their goods - Managers learnt to take quality for granted
- American’s technical advancements meant there was a lack
of competition hence they felt that continuous improvement
was unnecessary
What is MRP?
Materials requirement planning
schedules release of work based on (actual or forecasted demand)
Can be described as a PUSH system
Can lead to high inventory, space capacity issues
What are the two pillars of TPS?
Just in time
Jidoka
What is Jidoka?
Automation with human touch
Seperate man’s work & machine’s work
1) Discover an abnormality
2) Stop the process
3) Fix the immediate problem
4) Investigate and solve the root cause
What is Just-in-Time?
Takt time
Flow production
Pull system
What is Takt time?
Heart beat of manufacturing process
Calculated by available production time / customer demand
(excludes breaks, maintenance etc)
What does Just in time do?
Attacks waste
Streamlines production by reducing inventory
Exposes problems/bottlenecks caused by variability
What is the foundation of TPS?
Stability
What is cycle time?
available productive time / total units produced
(excludes breaks, maintenance, shift changeovers etc)
What is lead time?
Total time from placing an order to receiving a product.
Includes delivery etc
What are the seven types of waste?
Over production
Wait time
transportation
processing
inventory
motion
defects
Why is it important to balance Takt time?
reduces bottlenecks in production
social impact- shares difficulty equally between operators
What is Kanban?
Visual cue
ie kanban cards, traffic light system etc
