The Toyota House

Toyota Production System

Heijunka is the foundation of the Toyota Production system, and is the process of leveling and sequencing an operation.
If you are trying to have necessary working capacity to meet the production peak, it creates huge Muda (Waste) for people, material and equipment.

Toyota 1

Jidoka allows machines to operate autonomously by shutting down automatically if an abnormality occurs.
This prevents defective products from passing to the next process.

Two Main Elements :

1. Automation with human intelligence. (Example: Printer checks for low ink level)

2. Process stops to initiate action at point of occurrence. Countermeasure implemented to prevent repeat occurrence

Three Reasons to Stop a Process : Defective Material - Material Shortage - Equipment Breakdown

Just-in-Time provides the customer what is needed, when it is needed, in the quantity it is needed.

Three main elements

1. Single Piece Flow: Completing the process from start to finish continuously.

2. Pull Production: A system in which each process takes what it needs from the preceding process when it needs it and in the exact amount needed

3. TAKT Time: Frequency at which unit should be completed in order to meet customer demand

Kaizen means “Change for the better” or “Continuous Improvement”

A hands-on process of short duration to develop iterative solutions, with each iteration an improvement on the last.

Why implement ?

Motivation of employees - Waste reduction - Productivity increase - Quality improvement - Just In Time Delivery - Customer satisfaction

– Look for Ideas Everywhere – Get Your Hands Dirty – Participation of technicians/experts – they are the one who know the work (at least 50%)

– Tools Target Process Waste – Just Do It…20% Plan, 40% Do, 40% Re-Do – Trystorm…try-observe-improve, over & over

– Creativity Vs $$ … Spend $$ as if it were your own