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TPS Production System


TPS Production System Toyota Production System (TPS) – production control method, originally developed in Toyota Motor Company, whose basic idea is to maintain continuous product flow in an organization and at the same time to be able to react flexibly to the ever changing production requirements. It results in lean „just-in-time" manufacturing, when only essential products are produced in required quantity and time. Costs for surplus stock are eliminated, labour force is reduced and process efficiency is increased. Essential prerequisite for costs reduction is the following:
  • quantity control that enables the system to adopt to daily and monthly fluctuations regarding quantity and method of production
  • quality control ensuring that each sub process provides the subsequent process only with impeccable products
  • continuous improvement of labour force

TPS rests on two basic pillars: just-in-time production and a concept called jidoka - that means autonomous control of production defects ensuring no defective products will ever infiltrate the subsequent production process and affect it. In practice TPS is based on several basic procedures and methods, including but not limited to the following:
  • Kanban system (kanban = slip, card) – information system that helps to control quantity of parts manufactured in each sub process production, maintain the production flow and thus also the just-in-time production
  • method for equalization of production variations with changes in demand (Heijyunka)
  • standardization of work tasks
  • use of flexible labour force able to perform different operations (Shojinka)
  • encouragement of employees in terms of innovation submission and creative thinking (Soi, kufu)
 
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