What is the Toyota Production System?
What is the Toyota Production System (TPS)?
Toyota’s production system is an efficient production system that is accepted around the world by many of the companies and has generally been shown to be one of the most effective ways to make a profit and balance production along with the circulation of money. The Toyota Production System is a simple way to make things quick, fast and productive. It is well known for its efficiency and just-in-time concept that results in an ongoing product management process and a good self-defense plan for a business, not keeping quantities of defective products in stock. TPS is famous for its production management process that comes together in pairs, the Jidoka and Just-in-Time concept, in which a specific number of products are produced to avoid large amounts of stocks that are not necessary. Both the Jidoka and Just-in-Time concept are widely used in companies around the world and are guaranteed to be the two best ways to manage the production process and maintain stability in a company efficiently.
Its origin
From its name, ‘Toyota’ is a company from the land of the rising sun, Japan. Japan is in fact the most technological country in the world full of technology and a wide variety of rituals and cultural performances that captivates the world with its beautiful nature, as well as with its wise business management and productivity processes. Developed by Taichii Ohno, Toyota’s TPS or Production System works efficiently and is shared globally with all companies. Many Japanese philosophers at that time contributed ideas about process management and productivity in order to improve companies and improve their efficiency through products and their high quality. Eiji Toyoda gave employees and workers values and importance that increased productivity and teamwork within offices, colleges and companies.
The Jidoka
Jidoka is a simple concept of visualization and problem determination. It ensures that all machines or capitals work well without any technical problems. If any problems are detected or the machines are not working properly, the machines will stop automatically after normal processes are carried out. Jidoka is generally a quality test display concept that will assure companies of the quality of their products and minimize capital, stock malfunctions, as well as lost profits. With the Jidoka concept, high-quality products will be produced. These products of satisfactory quality will be passed on to the following processes. Jidoka is considered simple and technological due to its various installations of the andons or the problem display screen in different parts of the company that will show operators the problems detected by the system. These operators can work on many parts of the production system and can monitor the number of machines at the same time with the help of technology and a well-developed plan, the Jidoka concept. This concept will benefit the entire system by increasing productivity while improvements lead to better throughput.
Pros and cons of Jidoka
Pros:
1. Eliminate waste or defective or malfunctioning products
2. Ensure product quality
3. Provides safety to workers and work
4. Keeps Goals Targeted
5. More percentage of reaching the established profits and expectations
Cons:
1. High cost of technological tools
2. Specific target market
3. Results in unstable productivity
4. Strict rules and regulations
Just in time
Just-in-Time is a fast and fast concept on the production line that ensures companies their safety by eliminating waste and producing only what is needed by establishing the quantity of products that must be produced and when they must be produced, what which will include ways to store products safely. The Just-in-Time concept is mainly used in car or vehicle businesses that are largely concerned with vehicle production and transportation plans, including the period of time required to complete orders and the ways in which they are they transport the vehicles.
How Just-in-Time works
1. Once an order is placed, it should be delivered as quickly as possible to the first production line.
2. The assembly line or those in charge of the vehicle parts, such as wheels, colors and seats, must have all the parts well equipped and ready to work automatically as soon as possible after the order is placed.
3. The number or quantity of parts must be the same for both the assembly line and the part production process.
4. The above process group must have spare quantities of all parts of a vehicle and the company operator must recall at least one quantity.
By following 5 simple steps in the process or production line, eliminating waste and inconsistencies will ensure profit expectations as well as standard business requirements. One of the concepts within the Just-in-Time system is the Kanban system. Kanban systems use the idea of management and productivity of supermarkets. The Kanban system uses codes, serial numbers and names to make all parts of the production process easy and flexible. It will help to improve the structure of the production process, as well as to keep the processes running. The idea of storage in the supermarket provides the necessary amount of products in relation to the market demands and therefore convenient for customers because the products are in stock only in a limited quantity.
Pros and cons of the just-in-time concept
Pros:
1. The funds that were held and immobilized in inventories can later be used in other processes
2. Quick response to customer
3. Guaranteed product quality
4. Defect rates are reduced
5. Higher potential production
Cons:
1. Expensive and expensive to introduce
2. There are not enough products in stock
3. Not enough time to complete orders / productivity reconditioning
4. Strict rules and regulations
Resume
The Toyota Production System or the TPS is indeed an efficient way of ensuring product quality and ensuring that products are produced quickly and quickly. TPS enables high productivity and increased demand for products. Specific product components can be ordered accordingly; Large amounts of stocks are not kept and waste is effectively eliminated to achieve the company objectives that are set and oriented, as well as meet the standard requirements.