Acknowledgements ii Acknowledgements

2005 6 2005 6 2017 3 iii

Preface a must learn iv Preface

3 OJT Q&A v

Contents Part 1The Toyota Production System 1 What is the Toyota Production System?002 2 Production of many models in small quantities004 3 Move and Work008 4 Finding the Root Cause011 Part 2Just-In-Time 1 What is Just-In-Time?016 2 Workflow020 3 Synchronization023 4 A later process takes what is needed from an earlier process027 5 Eliminating Unnecessary Inventory030 6 Just what is needed, Only when needed, Only in the quantity needed033 Part 3Production Leveling 1 What is Production Leveling?038 2 Small Lot Production041 3 Changing Setup Quickly and Often044 4 Zero Fluctuation048 5 Diversification050 6 Rationalizing Production Processes053 vi Contents

Part 4Standard Work 1 What is Standard Work?056 2 Takt Time059 3 Work Sequence062 4 Standard In-Process Stock065 5 Standard Work Sheet067 6 Unreasonableness, Inconsistency, Waste071 Part 5Elimination of Waste 1 What is Elimination of Waste?076 2 Seven Types of Waste080 3 Operation Rate and Operational Availability086 4 Improving Efficiency090 5 Excess Manpower, Equipment and Inventory093 6 Production Quantity and Number of People096 Part 6Kanban Method 1 What is the Kanban Method?100 2 Types of Kanban Cards103 3 Rules of Kanban Use109 4 Prevent Over-Production112 5 Fine Adjustment114 Part 7Autonomation 1 What is Autonomation?118 2 Automation with a Human Element121 3 Visual Management124 4 Andon Board126 vii

Part 8 Labor-Saving, Manpower-Saving and the Flexible Manpower Line 1 What are Labor-Saving, Manpower-Saving and the Flexible Manpower Line?130 2 Labor-Saving132 3 Manpower-Saving135 4 Flexible Manpower Line138 5 Multi-Skilled Development141 Part 9Manpower Reduction 1 What is Manpower Reduction?146 2 Kaizen (in operation)148 3 Equipment Kaizen151 4 Multi-Machine Handling154 5 Multi-Process Handling157 Part 10Quality Assurance 1 What is Quality Assurance?162 2 Quality must be built into each process167 3 Mistake-Proofing169 4 Reacting to Abnormality172 Part 11 Manager, Supervisor and Teamwork 1 Manager, Supervisor and Teamwork176 2 Manager and Supervisor178 3 Teamwork180 4 OJT, Off-JT, QC OJT, Off-JT, QC-activities182 viii Contents

Part 12Safety, Maintenance and 5S 1 5S What are Safety, Maintenance and 5S?188 2 Safety190 3 Maintenance193 4 5S 5S196 Using Robots 1 Introducing Robots200 2 Responding to Labor Shortage202 3 How to Use Robots204 1 Going to See the Site 211 2 When We Find Defects... 218 3 On-the-Job Training (= OJT) 223 1 How-to230 2 QCDQuality Cost Delivery 234 3 240 Index243 References261 Columns 1 007 013 022 026 035 047 058 064 074 079 085 089 123 2 143 153 156 166 171 185 192 195 198 201 203 205 206 ix

1 Production Flow Processing Casting Forging Machining process Molding Press Body production start Body production finish Painting finish Final assembly Line off Assembly

1Part The Toyota Production System

1 What is the Toyota Production System? 2 Toyota Production System = TPS production system management system a well-known production system an efficient management system 002 Part 1 The Toyota Production System

a widely accepted production system a widely used management system a management system applicable to many different industries a production system that can be adapted to all operations of the company The Toyota production system helps increase production efficiency. By using the Toyota Production System properly, companies can enhance the management efficiency. TPS has improved the teamwork and efficiency of our organization. widely accept adapt operation efficient applicable industry help increase properly enhance efficiency implementation organization 003

2 Production of many models in small quantities production of small quantities of many products production of small quantities of many different models production of small quantities of many kinds production of small quantities of many types production of many models in small numbers production of many types in small quantities multi-kind and small quantity production Many companies have shifted from making large quantities of a few products to making small quantities of many products. 004 Part 1 The Toyota Production System

We must respond to demands for product variety by producing many models in small quantities. Their company has improved their manufacturing capabilities and succeeded in producing small numbers of a variety of products. multi-kind multi- multi-skilled technicianmultiangle drill quantity kind number shift respond demand variety capability succeed mass-production the economic benefits of a massproduction system a cost-reducing effect of mass-production a negative effect of mass- production 1 manufacture a product on a large scale produce large quantities of a particular item 005

These products are mass-produced in limited sizes. A mass-production system doesn t seem to work well when you are making many product varieties in small quantities. limited demand The average Japanese consumer has limited demand for low-end products. The potential demand for imported cars is relatively limited. diversification diversify diversity Our company has diversified the product lines and increased the market share. Most of our products can be customized to meet diverse customer demands. 006 Part 1 The Toyota Production System

Customer needs change rapidly. negative scale particular item seem to variety average low-end product potential relatively product line market share customize diverse rapidly 1 013 007