TOYOTA PRODUCTION SYSTEM

GROUP MEMBERS

Name ID

1. Mazharul Islam 121070702. Mobarak Hossain 121070693.Naimur Rahman 121070394.Md.Rafiqul Islam 121070375. Md.Saiful Islam 12107042

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Mazharul Islam ID - 12107070

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7 PRINCIPLES OF TOYOTA PRODUCTION SYSTEM Reduced setup time Small-lot production Employee Involvement and Empowerment Quality at the source Equipment maintenance Pull Production Supplier involvement

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PRODUCTION SYSTEM HOUSE

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Mobarak Hossain ID - 12107069

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JUST-IN-TIME

Produced according to what needed, when needed and how much needed.

Strategy to improve return on investment by reducing inventory and associated cost.

The process is driven by Kanban concept.

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Naimur Rahman

ID - 12107039

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KANBAN CONCEPT

Meaning- Sign, Index Card It is the most important Japanese concept opted by

Toyota. Kanban systems combined with unique scheduling

tools, dramatically reduces inventory levels. Enhances supplier/customer relationships and

improves the accuracy of manufacturing schedules. A signal is sent to produce and deliver a new

shipment when material is consumed. These signals are tracked through the refill cycle and

bring extraordinary visibility to suppliers and buyers.

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KAIZEN Meaning- Continuous Improvement Kaizen refers to a workplace 'quality' strategy

and related to various quality-control systems. It aims to eliminate waste (defined as

"activities that add cost but do not add value").

Kaizen is a daily activity whose purpose goes beyond improvement. It is also a process that, when done correctly, humanizes the workplace, eliminates overly hard work (both mental and physical.

It teaches people how to perform experiments using the scientific method and how to learn to spot and eliminate waste in business processes.

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Md.Rafiqul Islam ID-12107037

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JIDOKA Jidoka (meaning ‘autonomation’)-a term used

in Lean manufacturing meaning "automation with a human touch."

It is a quality control process used in the Toyota Production System which applies the following four principles:

Detect the abnormality. Stop. Fix or correct the immediate condition. Investigate the root cause and install a

countermeasure.

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JIDOKAwww.a2zm

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Md.Saiful Islam ID - 12107042

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LEAN MANUFACTURING

Lean manufacturing is a systematic method for the

Elimination of wastes within a manufacturing process.

Also lean manufacturing is a management philosophy

Derived mostly from TPS and focused on reduction of

The seven wastages to improve overall customer value.

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By this process customer can choose the exact Product they wanted in the exact quantity they

wanted.It is also known as supply on demand

manufacturing.It means the production process only belongs

after customer has placed the order. The order arrived

just in time in the factory as well as production line and supplies are regulated with exact requirement.

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Mobarak Hossain ID - 12107

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SEVEN WASTES TO IMPROVE OVERALL CUSTOMER VALUE [ MUDA ]

Transportation Inventory Motion Waiting time Over-production Processing Itself Defective Product (Scrap in

manufactured products or any type of business.)

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HEIJUNKA (PRODUCTION SMOOTHING)

Heijunka is Japanese term that refers to a system of production smoothing designed to achieve a more even and consistent flow of work.

Heijunka as a concept is closely related to lean production and just in time manufacturing.

A related visual scheduling board known as a heijunka box is often used in achieving heijunka style efficiencies.

The use of heijunka as well as broader lean production techniques helped Toyota massively reduce vehicle production times as well as inventory levels during the 1980s.

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