The Goals of Toyota Production System

The basic intent of the Toyota production system is to increase profits by reducing costs through the elimination of all waste such as inventory or labor that is too much.To achieve cost reductions, production must be quickly and flexibly adjust to changes in market demand without excess time on useless. Such ideas were achieved with the concept of JIT: produce the goods required, the amount required, and when necessary.


At Toyota, the Kanban system has been developed as a way to post production for a month and managing JIT. To implement the Kanban system, is required smoothing production by leveling the number and variety of spare parts by taking the last line of the raft. This reduction in time required for production orders, for a variety of spare parts should be produced quickly every day. This can be achieved with small lot size production or one-piece production and transport of one-piece. Production of a small lot can be achieved by shortening the time of preparation, and production of one piece will be achieved by dual-process workers who worked in a line of double-handling process. A standard operating routine will ensure completion of all tasks to process one unit of a product in one cycle time. Support JIT production by products that are 100 percent "good" will be guaranteed by Autonomasi (defect in autonomous control systems). Finally, improvement activities will contribute to the overall process by changing the default operating, repair certain defects, and finally, by improving employee morale.

IMPROVEMENT ACTIVITY

Toyota production system to integrate and achieve different goals (ie controlling the quantity, quality assurance, and respect for humanity) while pursuing the ultimate goal of reducing costs. Repair activity is a fundamental element of the Toyota production system; is what makes the Toyota production system really can work. Each employee mempuyai opportunity to give advice and propose improvements through a small group called Quality Control. The process of giving such suggestions enable improvements in control by adjusting the number of routine operations to changes in cycle time, improvements in quality assurance to prevent the recurrence of work disability and the machine breaks, and in honor of humanity by allowing each worker to participate in the production process.

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Layout Process for Shortening the Time Orders

Note the design or layout of the process in a factory. In the past, in this factory every machine out of five of the booth lathes, milling machines, and driller placed side by side: one machine is held by a worker, for example one only holds one turner lathe.

According to the Toyota production system ,The engine layout would be reformed to expedite the flow of production.Therefore, every worker will hold three types of machines. For example, one worker will hold a lathe, a milling machine, and a drilling machine at the same time. This system is called double-handling process (multi-process holding). In other words, single-function workers, a concept that was applicable at the Toyota factory, now a dual-function workers.

Shortening the Preparation Time

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One of the most difficult process in the current production is about preparation. In a pressing process, for example, common sense to determine that cost reduction can be obtained by continuously using one type of mold, thereby allowing the largest lot size and reduce the cost of preparation. However, in a state where the last process has been smooth production and reduce the dosage between the pons and the next line of the body, as a process preceding the pressing need to prepare quickly and frequently. This means changing the type of mold for the press in accordance with various types of products repeatedly ole taken the next process.