Lean Manufacturing and The Toyota Production System or (TPS)

Lean Production is a system of production developed within the manufacturing of automobiles. Initially developed for Toyota and by Toyota, additionally it is known as the Toyota Manufacturing System (TPS), and also the ‘just-in-time manufacturing‘ production system.

This system of manufacturing owes its conception to an engineer Taiichi Ohno who was working with Toyota. He focused on eliminating waste in conflict-torn Japan, and also on empowering the workers. He additionally reduced kit-stock and improved productivity. In doing so he went against the philosophy of Henry Ford who believed in shoring up resources in anticipation of what could be required within the future. To beat the futuristically envisaged scarcity of manufacturing assets, as Ford had executed earlier than him, the administration workforce at Toyota built partnership with the suppliers! By making the maximum use of multi-expert employees available on the factory, Toyota was able to flatten their administration construction and focus their sources in a versatile manner. Being an in-house and smooth transition and also because of aftermath of the 2nd World War, Toyota was able to make the changes quickly. Toyota emerged means forward of its opponents by doing so.

The ten guidelines of Lean Manufacturing can be greatest described as under:-

Reduce inventory

Get rid of waste

Maximize circulate

Pull production from buyer demand

Do it proper the first time

Meet customer requirements

Design for fast changeover

Empower workers

Accomplice with suppliers

Create a tradition of continuous improvement.

For a lay man the word ‘Lean’ could be finest defined by the straightforward language – ‘creating extra value for customers with lesser resources’. To be able to achieve this, ‘lean’ considering adjustments the focus of the administration from optimizing separate applied sciences, vertical departments and vertical belongings to optimizing the circulation of services via entire worth streams that circulation horizontally throughout technologies, departments and property to customers. This can be achieved by eliminating waste along the complete worth stream, as an alternative of remoted cases. It will also be achieved by creation of processes that require much less human effort, much less space and fewer time to extend production. In Lean Manufacturing the value of the shopper is recognized, and each effort is made to multiply it.

As we speak, the Lean system is being tailored by every organization. The lean system applies not only to the production line but to every business and every process. In plain phrases, it isn’t a tactic or a program but a way of life and thought, not for an individual solely but for the entire organization.

Some organizations favor to not use the word ‘lean’ and use their very own nomenclature, e.g.; the Toyota Manufacturing System (TPS). Most companies accomplish that to show that the program isn’t a short-time period cost reduction program as visualized by the final public. They want the public to understand how the company thinks, and operates and conducts its business.Just as a carpenter wants a vision of what to build to get the complete benefit of a hammer, Lean thinkers also want a vision earlier than picking up Lean tools.


3 August 2018

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