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The Toyota Production system is a major precursor of Lean Manufacturing. Founded on the conceptual pillars of 'Just-in-time' and 'Jidoka' (or, Automation with a Human Touch), the system was first built off the approach created by the founder of Toyota, Sakichi Toyoda and his son, Kiichiro Toyoda.
Read More: What is Lean?
The main target of the Toyota Production is to eliminate 3 key issues: Overburden, Inconsistency, and Waste - or 'Muri', 'Mura' and 'Muda', respectively. Theoretically, process improvement working like so:
- A process is created that is easily repeated, and provides results smoothly, thus eliminating Inconsistency in the production line (Muri).
- This reduction in Inconsistency minimises Stress, or Overburden (Mura), as there are less mistakes being made.
- The lack of Stress in turn massively reduces Waste (Muda), which is considered to occur in 8 forms:
Dan Markovitz, Founder/President of Markovitz Consulting, Author
The corporate landscape is full of Operational Excellence companies that have failed in their pursuit of the ‘Toyota Way.’
Trying to be like Toyota is a mistake. A “fit” organization has the ability to continually improve in a manner that delivers superior performance and results over the long haul.
This Operational Excellence example study, based on the Shingo Research Award-winning book, "Building the Fit Organization," distills the lessons from the Toyota Production System into six core concepts, in the easily understandable language of physical fitness and athletic excellence—no Japanese, no English jargon, and no references to Toyota. Give your team the knowledge to be faster, more competitive, and better able to win in your market.
The Toyota Production System is grounded on two main conceptual pillars:
With 'Just in Time', a product is efficiently built within the shortest possible period of time by adhering to the following:
For the Just-in-Time system to function, all parts that made and supplied must be meeting predetermined quality standards. This is achieved through Jidoka.