Toyota Kunban System

Toyota Production System and Kanban system Synopsis

Materialization of just-in-time and respect-for-human system

The Toyota Production System (TPS) is production system, developed by Toyota, which comprises its management philosophy and practices. The system is built upon 2 major pillars:

Just in Time Production: Only the necessary products, at the necessary time, in necessary quantity are manufactured, with the stock in hand drawn to minimum

Respect for Human: Workers are allowed to display in full their capabilities through active participation in running and improving their own workshops

Japan’s lack of natural resources which made them produce better quality goods having higher added value and at an even lower production cost.Japanese concept of work, such as consciousness and attitude, differed from that held by the European and American workers. These traits have been reflected in the enterprise by providing

lifetime employment system,

labour unions by companies,

little discrimination between shop workers and white-collar staff, and

chances available to workers for promotion to managerial positions

Basic Concepts of the TPS

Cost cutting by thorough removal of waste: This involves making up a system that will thoroughly eliminate waste by assuming that anything other than the minimum amount of equipment, materials, parts, and workers (working time) which are absolutely essential to production are merely surplus that only raises the cost.

Just in Time Production: 'Just in time' manufacturing consists of allowing the entire production process to be regulated by the natural laws of supply and demand, which is demand driven, and producing only when required. This is typically characterized by:

Withdrawal by subsequent processes

Single piece flow

Leveling of production

Elimination of waste from over producing

Jidoka: In Japanese 'jidoka' means automation. Toyota took it one step further by calling it 'automation with a human...