Toyota Production System

Shopfloor Management

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 The Toyota Way

What is The Toyota Way ?

is a set of principles and
behaviours that underlie the
Toyota Motor Corporation’s
management approach and
production system.

What is Lean ?
is a systematic method for the
elimination of waste (Muda) within
a manufacturing system

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 Lean Manufacturing
Is a set of principles and behaviours which shortens
the time between the customer order and the
product build / shipment by eliminating sources of
waste and give added value

Business as Usual
CUSTOMER
WASTE PRODUCT
ORDER BUILT & SHIPPED

Time
Selling
Price
Lean Manufacturing
PROFIT PROFIT
CUSTOMER PRODUCT
ORDER BUILT & SHIPPED

COST COST
Time (Shorter)

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 4P Model of Toyota Way

Toyota’s
12. Continual organizational Learning through Kaizen
Term 13. Go See for yourself to thoroughly Understand the Situation
Problem
(Genchi Genbutsu)
Solving
(Continuous
14. Make decisions slowly by Consensus, thoroughly considering all
Improvement & options; Implement Rapidly
Learning)

9. Grow Leaders who live the Philosophy

People and Partners 10. Respect, develop, and challenge your People and Teams
(Respect, Challenge, 11. Respect, challenge and help your Suppliers
& Grow Them)
2. Create process “flow” to surface problems
3. Use pull system to avoid over production
4. Level out the workload (Heijunka)
Process 5. Stop when there is a quality problem (Jidouka)
(Eliminate Waste) 6. Standardize tasks for continuous improvement
7. Use Visual Control so no problems are hidden
8. Use only reliable, thoroughly tested technology

Philosophy 1. Base management decision on a Long-term

(Long-Term Thinking) philosophy, even at the expense of short-term
financial goals

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House of TPS

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 5S / 5R

Modal dasar untuk menemukan Waste / Pemborosan !!!

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Waste / Pemborosan

+ 8. Non utilize resources