Presentation1.pptx tps
-
Upload
love-tanna -
Category
Documents
-
view
221 -
download
0
Transcript of Presentation1.pptx tps
-
8/14/2019 Presentation1.pptx tps
1/17
-
8/14/2019 Presentation1.pptx tps
2/17
INTRODUCTION
An integrated socio-technical system
Comprises philosophy and practices.
The TPS organizes manufacturing and logistics for
the automobile manufacturer
The system is a major precursor of the more generic
Lean manufacturing(elimination of wastes)
TPS specifically and collectively calls seven wastes
Muda
-
8/14/2019 Presentation1.pptx tps
3/17
HISTORY
Created by - Sakichi Toyoda; his son, KiichiroToyoda; & a production engineer by the name ofTaiichi Ohno.
Set up an automobile-manufacturing operation in the
1930s
Kiichiro studied Henry Ford's system
Thus was determined to adapt this system to the small
production volumes of the Japanese market.
In his system, each process produced only the kindsand quantities of items that the next process in thesequence needed and only when it needed them.
-
8/14/2019 Presentation1.pptx tps
4/17
TPS TERMS
Just In Time (JIT).
Jidoka (Autonomation)
Kaizen (Continuous Improvement)
Andon
Pokayoke
Muda
-
8/14/2019 Presentation1.pptx tps
5/17
TPS CONCEPTS
-
8/14/2019 Presentation1.pptx tps
6/17
7 PRINCIPLES OF TPS
Reduce setup times :Employees at Toyota were made responsible for their own setupsthus reducing the wastefulness of this process that ultimately addsto value to the customer and takes up valuable in process labortime and equipment.
Small-lot production :The process of economically producing a variety of things in smallquantities rather than producing things in large batches.
Employee involvement and empowerment :
Employee are divided into teams and even those in supervisorypositions work along side other employees on the production lineas part of the team.
-
8/14/2019 Presentation1.pptx tps
7/17
Quality at the source :
Product defects are identified and corrected as soon as they
occur or at the source.
Equipment maintenance :
Operators of the equipment are also assigned to take care oftheir maintenance since these should be the individuals whoknow the equipment best.
Pull production :
The work performed at each stage of the process is dictatedsolely by demand for materials from the immediate next stage(also known as "Just in Time").
Supplier involvement :
Suppliers are treated as partners and are also trained in the TPSmethods.
-
8/14/2019 Presentation1.pptx tps
8/17
5 S APPROACH
Seiri(sort) - keep only what is absolutely necessary, get rid of
things that you don't need
Seiton(set in order) - create a location for everything,
Seiso(shine) - clean everything and keep it clean
Seiketsu (standardize)- implement Seiri, Seiton and Seiso plantwide
Shitsuke(sustain) - assure that everyone continues to follow therules of 5s
-
8/14/2019 Presentation1.pptx tps
9/17
TPS- LEAN 6 SIGMA
TPS-Lean Six Sigma, the first holistic program that addresses notonly the business needs, but the human needs as well
The four fundamental elements of TPS-Lean Six Sigma Cycle:
Formulating- This phase involves the formulation of theOrganizational, Project, and Personal Balanced Scorecard.
Deploying- All stakeholders participate in the business strategy bycommunicating and cascading the corporate scorecard to thescorecards of other business units and teams, and finally linking theteam scorecard to the individual performance .
Improving- This means continuously improving both the business
system processes, and the talent. The focus here is on correctingmistakes, improving existing capabilities.
Developing and Learning-The emphasis is on job-related talentmanagement, business process learning, and to manage and use thetalents within the organization effectively.
-
8/14/2019 Presentation1.pptx tps
10/17
"Under a 'push' system, there is little opportunity for workers togain wisdom because they just produce according to theinstructions they are given.
In pull system, workers are asked to use their heads about whatneeds to be made and how quickly it needs to be made
T actually stands for "Thinking" as well as for "Toyota."
PULL SYSTEM TO AVOIDOVERPRODUCTION
-
8/14/2019 Presentation1.pptx tps
11/17
KANBAN SYSTEM
At Toyota, empty bin (a kanban) is send upstream after a demandinstance.
It is a signal to refill it with a specific number of parts or sendback a card with detailed information about the part location.
Instead of using sophisticated computer scheduling techniques,this is a simple, effective and visual system of managing andensuring the product flow and JIT production system.
Toyota philosophy about kanban: Kanban is an organizedsystem of inventory and as per TPS, inventory is waste, whether
it is in pull system or push system. So kanban is something youstrive to get rid of.
Toyota uses kanban to force process improvements.
-
8/14/2019 Presentation1.pptx tps
12/17
-
8/14/2019 Presentation1.pptx tps
13/17
ANDON SYSTEM
When the equipment shuts down because of a quality problem,flags or light, usually with accompanying music, signal thathelp is needed to solve the problem.
This signaling system is called the andon system at Toyota also
called as fixed-position line system.
When a workstation in the assembly line signals a problem, theproduction line is not stopped immediately.
The manufacturing team has until the product moves to the next
workstation to respond and address the problem, before theandon turns red and stops the assembly line.
-
8/14/2019 Presentation1.pptx tps
14/17
If the problem is small enough that can be solved in the lead-time between two workstation, 100% quality is achievedwithout stopping the line.
If the problem is complex, the team leader can conclude that theline should stop.
In TPS, the workstation detects the defects by usingcountermeasures and error-proofing (poka-yoke).
Applications of andon system to service organizations like call-center are obvious!
Andon system
-
8/14/2019 Presentation1.pptx tps
15/17
HOW CAN TPS HELP ANORGANIZATION
Identify and enhance customer perceived value
Decrease waste and cost in the manufacturing process
Improve product quality and on-time delivery
Develop a competitive world class manufacturing operation
-
8/14/2019 Presentation1.pptx tps
16/17
CONCLUSION
In Ohnos teaching, TPS can be related to a tale of theslower but consistent tortoise causes less waste and ismuch more desirable than the speedy hare that racesahead and then stops occasionally to doze
-
8/14/2019 Presentation1.pptx tps
17/17
AKSHAY KASBEKAR (283085)KHUSHBU MAGIYA (283089)
SHOBNA PATEL (283100)
LOVE TANNA (283115)
THANK YOU