Toyota Production System guide to eliminating waste and continuous improvement

Toyota Production System KAIZEN NAEEM BHAI

Change Better Make it better ( Improvement )

Getting Started What is a Manufacturing Company ? Make good quality products Selling to Customer Earn Profit Guarantee employee’s better life Bring prosperity to people

Getting Started What is a good Quality product? お客様が満足する製品我々の給料は、お客様に製品を買ってもらい、その代金の中から支払われる。　すなわち我々の料の源は、お客様である。従って、続けて給料を貰うには、私達が造った製品をお客様に続けて買ってもらはねばならない。それには、私達が造った製品にお客様がいつも満足して貰うことが大切である。 Which satisfies the customer ,[object Object],[object Object],[object Object],[object Object],What is Customer Satisfaction?

Cost,Profit & Price Profit Cost Selling Price Selling Price = Cost + Profit Cost & Profit Profit = Selling Price - Cost Selling Price (Rs) How to earn more profit? Increase the selling price Reduce the cost

Cost,Profit & Price Material cost Purchased Parts cost Other cost Facility cost The expenses depend upon the method of manufacturing Every company is same (No big difference in a cost components) There is a difference depending on industry Cost Cost (Expense) Based on TPS Product Manufacturing and the cost KAIZEN Minimum Investment & Maximum Profit

TPS What is MUDA (Waste)? Identified by Tenchi Ohno-Japan Waste is the use of any material or resource beyond what the customer requires and is willing to pay for.

TPS MURI (overburden) MURA (unevenness) MUDA (waste) Value- Added Work Motions of Worker MUDA= Non Value-Added Work Non Value-Added Work Customer pays money only for Value-Added Work

TPS waste of overproduction Waste of waiting Waste of transportation Waste of processing itself Waste of inventory Waste of movement Waste of making defective products 7 Types of Muda

Inventory ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

Over Production ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

Motion ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

Waiting ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

Transportation ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

Over processing ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

Non-Right First Time (Scrap, Rework and Defects) ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

TPS Over Burden Adding work without eliminating Muda Understanding of Adding Work Eliminating Muda through Kaizen Adding Work in Saved Time = work MUDA work work MUDA MUDA Adding Work No Over Burden work work MUDA KAIZEN MUDA work MUDA = Adding Work

TPS Minimize Lead Time Minimize Non Processing Time Many types of MUDA will be highlighted when we minimize the Non Processing Time Lead Time = Processing Time + Non Processing Time = + = LEAD TIME Lead Time : time required to process from start to end (i.e. from raw material processing till packing goods)

Eliminate all MUDA from work site(NO.1) Injection Shop= Ground Floor Assembly Shop= 1 st Floor Ground Floor Ground Floor+ Use of Trolley [Before] [After]

Eliminate all MUDA from work site(NO.2) ﾗｲｾﾞﾝ　ﾋﾞﾃﾞｵ Make Process Flow Video-3 Video-4 punching Jig Assy Jig

Countermeasure (Example-3) ｻｰﾓｿﾙ Waste of processing itself Waste of Inventory(W.I.P) Three drill bits for three holes ,[object Object],[object Object],[object Object],[object Object],[object Object],7.0mm 4.0mm 5.5mm

Let’s move towards continual Kaizen Thank You

Toyota Production System guide to eliminating waste and continuous improvement

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