Lean Tools PDF

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Key concepts of TPS

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TPS was established based on two key concepts:
Just-in-time (JIT)
Jidoka
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www.otifas.com ___________________________________
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Just-in-time (JIT)
Toyota defines JIT as the right part at the right time in the right amount
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at the right place. Kiichiro devised and fine tuned his just-in-time
philosophy during the formative years of Toyota Motor Corporation
(TMC). JIT reduced in process inventory and efficiently produced only ___________________________________
precise quantities of pre-ordered items.
TMC applied this lesson to the production areas, raw materials and
finished item stores. They reduced the amount of inventory to a level that
is needed only for a small period of time. Orders from their suppliers were ___________________________________
also reduced to small quantities. They did so without adversely affecting
the efficiency of production. In fact, efficiency went up. This was JIT
inventory system.
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Just-in-time (JIT)
JIT brought down the capital locked in the system. At the same time,
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there were very important side benefits. These were:
Very low lead times. Customers got products as and when they
wanted ___________________________________
Much better quality. Defects were detected very soon after production
and acted upon straightaway.
Lower shops and stores floor area requirements. This was because of ___________________________________
smaller quantities of work in process.
A combination of above factors gave TMC a huge competitive advantage.
It finally made it the best automobile manufacturer in the world from the
point of view of value for money as perceived by the end customer. ___________________________________
While low inventory levels were key outcomes of the TPS, an important
element of the philosophy behind its system was to work intelligently and
eliminate waste.
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Jidoka
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Jidoka can be loosely translated as automation with a human touch. It
means that when a problem occurs, the equipment stops immediately,
preventing defective products from being produced. Jidoka is also
referred to as autonomation equipment endowed with human ___________________________________
intelligence to stop itself when it has a problem.
As per this philosophy, quality must be built in during the manufacturing
process. If a defective part or equipment malfunctioned is discovered, the ___________________________________
machine concerned automatically stops, and operators stop work and
correct the problem.
For the Just-in-time system to function, all of the parts that are made and
supplied must meet predetermined quality standards. In other words, the ___________________________________
parts must be built right the first time since there is no buffer to fall back
upon in case there is a quality problem. This is achieved through Jidoka.
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Lean tool and supporting strategies
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There are a number of tools and supporting strategies that are used for
implementing lean manufacture. These are described briefly
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Quick changeover and setup reduction
This is also known as single minute exchange of dies (SMED). It is a

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series of techniques pioneered by Toyota engineer Shigeo Shingo for
quick changeover of production machinery.
Small lots and no overproduction will be possible if setup times for the ___________________________________
machines are large
It is therefore necessary to minimize setup times specially for semi
versatile machinery such as big stamping presses from months to
hours and even minutes.
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Pull system and Kanban
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Pull systems, inspired by American supermarkets, is a system of
succession of production and delivery instructions from downstream to
upstream activities.
Nothing is produced by the upstream suppliers until the down stream ___________________________________
customer signals a need, thereby preventing overproduction.
Kanban is a signaling system to trigger action for material replenishment.
As its name suggest, Kanban historically uses cards to signal the need ___________________________________
for an item. However, other devices such as plastic markers (Kanban
squares) or balls (often golf balls) or an empty part-transport trolely or
floor location can also be used to trigger the movement, production, or
supply of a unit in a factory. ___________________________________
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Work organization and 5S system
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5S is a deceptively simple system for house keeping and work re-
organization described by:
Sort: Remove all unnecessary items.
Set in order: A place for everything, everything in place.
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Shine (and inspect): Clean up
Standardize
Sustain ___________________________________
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Value stream analysis and Value stream mapping
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Value stream analysis is the analysis of the specific activities required to
design, order and provide a specific product, from concept to launch,
order to delivery, and from raw materials into the hands of the customer.
Value stream mapping is the identification of all the specific activities ___________________________________
occurring along a value stream for a product or a product family.
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Total Productive Maintenance
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This is a series of methods to ensure that every machine in a production
process is always able to perform its required tasks so that production is
never interrupted.
Nippon Denso (a Toyota group company) was the first organization to ___________________________________
introduce Total Productive Maintenance (TPM) in 1971.
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Cellular Manufacturing / Cell design
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This is the layout of machines of different types performing different
operations in a tight sequence, typically in a U shape.
This permits single-piece flow and flexible deployment of human effort for
multi-machine working. ___________________________________
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One piece flow
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One piece flow refers to the concept of moving one work piece at a time
between operations within a work cell. Such a system flexible changes
according to customer demand and is efficient at the same time. It
originated from the Fords system of continuous material flow (as ___________________________________
illustrated by the assembly line)
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Visual control
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Visual control provides information to guide everyday actions.
Traffic signals and signs are most common examples.
It is powerful tool for enabling good decision making at the micro level.
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Takt Time
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Takt time is the heart beat of one-piece flow. It is fundamental to lean
manufacturing.
Takt is a general word for rhythm or meter.
It is the rate of customer demand the rate at which customer is buying ___________________________________
product.
It involves matching the pace of production to the pace of the actual sale.
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Team building
Make an ongoing effort to teach individuals how to work together as

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teams towards common goals.
Teamwork is something that has to be learned.
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Employee involvement and empowerment
Employee development and leadership development is at the heart of

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TPS.
Involvement goes hand in hand with empowerment.
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Balanced flow (Heijunka)
Heijunka means leveling of production by both volume and variety.

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It is a pre-requisite for just-in-time delivery and pull system.
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Andon
Andon is a signalling system used by employees for Jidoka, i.e., for

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stopping the production line whenever there is a serious defect or a
problem. It is another aspect of employee empowerment.
This encourages a sense of responsibility amongst employees towards ___________________________________
elimination of defects and towards better quality.
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Standard operations procedure
This refer to the use of stable, repeatable methods everywhere to

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maintain the predictability, regular timing, and regular output of
processes.
It is the foundation for flow and pull. ___________________________________
Without standardization and stability of existing methods, we cannot even
access the extent of improvement brought about by the new methods.
Standardization is often confused with rigidity and lack of innovation. ___________________________________
In fact, Toyota has found just the opposite to be true.
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Problem Solving
Employee will not get involved and feel responsible unless they have a
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reasonably good expertise in solving daily problems.
All the employees are encouraged to learn simple problem solving
techniques such as data collection, flowcharts, pareto charts, trend ___________________________________
analysis, cause and effect analysis, 5Whys, etc.
Problem solving should be done at the actual place (where the problem
occurs) to see what is happening (genchi genbutsu).
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Poka-Yoke
This is also called mistake-proofing or error-proofing.

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The workstations are so designed that it is nearly impossible for
operators to make errors.
This is an important step for ensuring quality. It is also a requirement for ___________________________________
maintaining single piece flow.
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Key concepts of TPS

Copyright RS OTIFAS (P) Ltd India

This is also known as single minute exchange of dies (SMED). It is a

Make an ongoing effort to teach individuals how to work together as

Employee development and leadership development is at the heart of

Heijunka means leveling of production by both volume and variety.

Andon is a signalling system used by employees for Jidoka, i.e., for

This refer to the use of stable, repeatable methods everywhere to

This is also called mistake-proofing or error-proofing.

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