Toyota's remarkable execution in
assembling has been broadly known and
acknowledged by different organizations everywhere throughout the world.
Particularly when some well-known organizations like GM, Ford, and Chrysler
conditionally made a Toyota-like generation framework that expansion
profitability in numerous viewpoints.
The
things that using to help increase productivity in many perspectives
are find it difficult to imitateThis article tries to decode the Totota Productions system that related to activities, connections, and production flows and why its operations are extremely flexible and adaptable..
The
motivation behind why concentrate on those variables is on account of they are
constantly tested and pushed to high level of performance and this has obviously
support to continuous improvement which deliver the best Quality in
shorter lead time with affordable price to customer.
The researchers studied the Toyota
production system that contain the manufacturing process, assembly, service
functions, training, supervision, and logistics, design and so on. They
identified that the success production system is scientific approach. All the
specifications built based on hypotheses that can be tested and followed
scientific methods. The Toyota Production system itself empowered all level of employees
to function well. The Study has revealed some rules of TPS which guide the
design, operation, and improvement of every activity, connection, and pathway
for every product and service.
The first rule: How People Work.
TPS made all the work is highly specified to content, sequence, timing, and outcome. They
focus on the standard work process which can reduce the variance among system function
and roles. If all are preforming to the standard well defined way. It can easily
recognized the abnormalities. So team leaders can quickly help to solve the
problem and make sure the continuity of flow of work. All process divided and designed
accordingly to get the work in order. So that team members is
capable for performing effectively and make the desired result
The second rule: How People connect in this system
Every customer supplier connection is direct,
and there must be an unambiguous yes-or-no way to send requests and receive
responses. Every connection is standardized and direct.
It is identified the requirement of supplier and customers. The both parties are
connected through a Kanban cards. The system is well organized and designed. The workers are determined by the types of problems expected to occur, the skills and capacity
of the team leaders. They have empowered team to solve their
problem at their level and reduce the possibility of variance which improved
the flexibility and adaptability between connections in the system.
The third rule: How the Production Line is constructed.
Production lines are set up that product and service flows can along a simple, specific path Tbe
path way is not changing unless the production line is specifically redesigned.
The continuous flow has been setup with each machine or a person. At different companies, each type of parts followed the same efficient production path through
the plant. The
specified pathway make sure different production cells are connected and fully
occupied. It improves consistency and simplify the material handling and
scheduling and address abnormalities quickly
The fourth role: How to Improve.
Workers at the lowest feasible level,
guided by a teacher improve their own work processes using scientific methods.
Toyota openly teaches people how to improve, not expecting them to learn strictly
from personal experience. All the defined goals and predictions depends on hypotheses. The process remains the same at all
levels without exceptions. They encourage collaborative problem solving
and the improvements ideas.
Every one of the standards make individuals
able to do and in charge of doing and enhancing their own particular work. The standard
work process and connection of various levels can discover and tackle and solve
issues quickly. TPS has created a workplace of scientists, each employing the
scientific method to evaluate processes and create plans for improvement and achieved
dynamic growth market. So if company can adapt in to these rules, there is obvious
opportunity to improve their productivity and better performance as like
Toyota.
