Toyota Manufacturing System

Introduction

Lean Synchronization

Lean synchronization is the aim of achieving a flow of products and services that always delivers exactly what customers want, in exact quantities, exactly when needed, exactly where required, and at the lowest possible cost.

Lean synchronization is, at the same time, a philosophy of operations, and a set of ‘lean’ techniques that include ‘JIT’ methods of planning and control.

To achieve lean synchronization three actions must be taken:

1. Follow the“kaizen” approach that eliminates waste in seven categories: 1. Overproduction, 2. Waiting imposed by an insufficient work sequence, 3. Inventory in excess, 4. Process that doesn´t add value, 5. Unnecessary handling that disturbs the work flow, 6. Motion that does not contribute to work and 7. Correction necessitated by defects. Examples of the seven categories are such as people/machines waiting for work, work waiting for people/machines, excess travelling, errors, inventory, non value added activities, material arrive too soon or too late, set up delays, machine breakdowns, re-work.

2. Involve all the people within the operation in the shared task of smoothing flow and eliminating waste. This is about sharing information and effective communication. Toyota often uses a set of ‘basic working practices’ to ensure involvement.

3. Adopt continuous improvement principles. Because pure lean synchronization is an aim rather than something that can be implemented quickly, it requires the continual application of incremental improvement steps to reach it.

Toyota Production System

Toyota's commitment to a world class, quality automobile is entrenched in the entire manufacturing philosophy. From the development stages to manufacturing a product, the quest for superior quality is evident.

• Philosophy - The cornerstone of Toyota's quality control system is the role of the team members in the production process.

o encouraging an active role in quality control,

o utilizing...