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This book utilizes historical evidence to describe the development of the Toyota Production System (TPS). The development of TPS typifies the transformation of production control in interchangeable industries in the twentieth century. Much of the extensive literature available on TPS has been geared toward describing TPS from a number of different perspectives. Many researchers consider TPS distinct from American mass-production systems. Although TPS (and, more generally, the production control systems in the Japanese assembly industry) has differentiated itself from similar US production systems, the evolution of TPS is largely attributable to attempts to learn from, imitate, and modify pre-World War II US production methods. Through these efforts, TPS has achieved levels of efficiency in Japan comparable to those of US production systems. Additionally, a reliance on Information and Communication Technology (ICT) in relation to production control has facilitated the development of TPS. The literature on TPS, however, has largely ignored the vital relationship between ICT and production control due to an inordinate focus on “Kanban.” Kanban translates to “signboard” in Japanese but is used to refer to an organic linkage between work in preceding and subsequent production processes. This book sheds light on the development of a fully digitalized Bill of Materials (BOM) at Toyota, behind its Kanban and production control.
This is the "green book" that started it all -- the first book in English on JIT, written from the engineer's viewpoint. When Omark Industries bought 500 copies and studied it companywide, Omark became the American pioneer in JIT. Here is Dr. Shingo's classic industrial engineering rationale for the priority of process-based over operational improvements in manufacturing. He explains the basic mechanisms of the Toyota production system, examines production as a functional network of processes and operations, and then discusses the mechanism necessary to make JIT possible in any manufacturing plant. Provides original source material on Just-ln-Time Demonstrates new ways to think about profit, inventory, waste, and productivity Explains the principles of leveling, standard work procedures, multi-machine handling, supplier relations, and much more If you are a serious student of manufacturing, you will benefit greatly from reading this primary resource on the powerful fundamentals of JIT.
The Toyota Way Fieldbook is a companion to the international bestseller The Toyota Way. The Toyota Way Fieldbook builds on the philosophical aspects of Toyota's operating systems by detailing the concepts and providing practical examples for application that leaders need to bring Toyota's success-proven practices to life in any organization. The Toyota Way Fieldbook will help other companies learn from Toyota and develop systems that fit their unique cultures. The book begins with a review of the principles of the Toyota Way through the 4Ps model-Philosophy, Processes, People and Partners, and Problem Solving. Readers looking to learn from Toyota's lean systems will be provided with the inside knowledge they need to Define the companies purpose and develop a long-term philosophy Create value streams with connected flow, standardized work, and level production Build a culture to stop and fix problems Develop leaders who promote and support the system Find and develop exceptional people and partners Learn the meaning of true root cause problem solving Lead the change process and transform the total enterprise The depth of detail provided draws on the authors combined experience of coaching and supporting companies in lean transformation. Toyota experts at the Georgetown, Kentucky plant, formally trained David Meier in TPS. Combined with Jeff Liker's extensive study of Toyota and his insightful knowledge the authors have developed unique models and ideas to explain the true philosophies and principles of the Toyota Production System.
It was the oil shock in the fall of 1973 that drew attention to our Toyota Production system. This was because in the slow growth economy which followed, Toyota Motor Company showed a relatively stronger resistance to recession than other companies.The Toyota approach was the result of many years trial and error as searched for a way to survive in competition with the mass production system already well established in Europe and America. It is a product of the Toyota history which started with Mr. Sakichi Toyota and has continued through Kiichiro Toyota to the present.From the beginning we felt we had some original ideas particularly suited to the economic environment of Japan. So, we did not want other companies especially those of the advanced countries, to understand it easily. Consequently we practiced the system and other techniques without publicizing them. Thus it is only natural that our system was not understood easily. Recently I heard often from the outside that there seems to be some sort of secret in the Toyota production system and in "kanban", which is the method of operating the system. We have received many direct and indirect inquiries from many people on the Toyota method of making things. They were not only from people in business, but from professors who are teaching production management in the universities and management consultants.We are grateful for this interest on the Toyota Production system. However as the attention grows and as more people in the business in this country study the subject, there seems to be misunderstanding in some cases or, sometimes certain convenient portion are abused. One specific example is to make a shortcut conclusion that Toyota Production System is a "Kanban system", but factually wrong. "Kanban" is one of the operational means of the Toyota Production System and just the adoption of "Kanban" alone does not mean that productivity will rise accordingly. And the intent of improving the record of a parent firm by "harassing the subcontractors" is entirely out of character with the idea of the Toyota Production System.So in order for others to understand and apply Toyota Production system correctly I have written this book. In order to ensure correct understanding, emphasis was placed on the ideas and principles involved rather than giving many specific examples. I would like to tell this to readers in advance. March, 1973Taiichi Ohno
Si usted quiere entender como se origino el sistema de producci?n Toyota y por que tiene exito, debe leer este libro. Aqui encontrara una introducci?n avanzada del justo a tiempo. El mundo le debe mucho a Taiichi Ohno. Nos ha demostrado como fbricar con mayor eficacia, como reducir costos, como producir una mayor calidad, y a examinar atentamente como nosotros, en nuestra calidad de seres humanos, trabajamos en una fbrica. El relato que Ohno cuenta en este libro es brillante. Deberia ser leido por todos los gerentes. No es solo un relato acerca de la fabricaci?n; sino tambien sobre como dirigir exitosamente una empresa.
This is an honest look at the origins of lean, written in the words of the people who created the system. Through interviews and annotated talks, you will hear first-person accounts of what these innovators and problem-solvers did and why they did it. You¿ll read rare, personal commentaries that explain the interplay of (sometimes opposing) ideas that created a revolution in thinking.
The Just-in-time (JIT) manufacturing system is an internal system in use by its founder, Toyota Motor Corporation, but it has taken on a new look. Toyota Production System, Second Edition systematically describes the changes that have occurred to the most efficient production system in use today. Since the publication of the first edition of this book in 1983, Toyota has integrated JIT with computer integrated manufacturing technology and a strategic informa tion system. The JIT goal of producing the necessary items in the necessary quantity at the necessary time is an internal driver of production and operations management. The addition of computer integrated technology (including expert systems by artificial intelligence) and information systems technology serve to further reduce costs, increase quality, and improve lead time. The new Toyota production system considers how to adapt production schedules to the demand changes in the marketplace while satisfying the goals of low cost, high quality, and timely delivery. The first edition of this book, Toyota Production System, published in 1983, is the basis for this book. It was translated into many languages including Spanish, Russian, Italian, Japanese, etc., and has played a definite role in inspiring production management systems throughout the world.
COMMEMORATING THE 100th BIRTHDAY OF TAIICHI OHNO Businesses worldwide are successfully implementing the Toyota Production System to speed up processes, reduce waste, improve quality, and cut costs. While there is widespread adoption of TPS, there is still much to be learned about its fundamental principles. This unique volume delivers a clear, concise overview of the Toyota Production System and kaizen in the very words of the architect of both of these movements, Taiicho Ohno, published to mark what would have been his 100th birthday. Filled with insightful new commentary from global quality visionaries, Taiichi Ohno’s Workplace Management is a classic that shows how Toyota managers were taught to think. Based on a series of interviews with Ohno himself, this timeless work is a tribute to his genius and to the core values that have made, and continue to make, Toyota one of the most successful manufacturers in the world. "Whatever name you may give our system, there are parts of it that are so far removed from generally accepted ideas (common sense) that if you do it only half way, it can actually make things worse." "If you are going to do TPS you must do it all the way. You also need to change the way you think. You need to change how you look at things." -- Taiichi Ohno "This book brings to us Taiichi Ohno's philosophy of workplace management--the thinking behind the Toyota Production System. I personally get a thrill down my spine to read these thoughts in Ohno’s own words." -- Dr. Jeffrey Liker, Director, Japan Technology Management Program, University of Michigan, and Author, The Toyota Way Based on a series of interviews with Taiicho Ohno, this unique volume delivers a clear, concise overview of the Toyota Production System and kaizen in the very words of the architect of both of these movements, published to mark what would have been his 100th birthday. INCLUDES INSIGHTFUL NEW COMMENTARY FROM: Fujio Cho, Chairman of Toyota Corporation Masaaki Imai, Founder of the Kaizen Institute Dr. Jeffrey Liker, Director, Japan Technology Management Program, University of Michigan, and author John Shook, Chairman and CEO of the Lean Enterprise Institute Bob Emiliani, Professor, School of Engineering and Technology, Connecticut State University Jon Miller, CEO of the Kaizen Institute
Lean Thinking was launched in the fall of 1996, just in time for the recession of 1997. It told the story of how American, European, and Japanese firms applied a simple set of principles called 'lean thinking' to survive the recession of 1991 and grow steadily in sales and profits through 1996. Even though the recession of 1997 never happened, companies were starving for information on how to make themselves leaner and more efficient. Now we are dealing with the recession of 2001 and the financial meltdown of 2002. So what happened to the exemplar firms profiled in Lean Thinking? In the new fully revised edition of this bestselling book those pioneering lean thinkers are brought up to date. Authors James Womack and Daniel Jones offer new guidelines for lean thinking firms and bring their groundbreaking practices to a brand new generation of companies that are looking to stay one step ahead of the competition.
This book explains the production methods and future trajectories for the Japanese car company through the strategic development of Toyotas automobile manufacturing both in Japan and overseas as follows: Part I gives an overview of the book based on the Toyota Production System (TPS), its advanced production management principles and its aim to create the simultaneous realisation of quality and productivity via process control and process improvement, with priority given to the customer. In Chapter One, the author describes the outline of the characteristic, aim, and validity" of this book. Chapter Two focuses on the progress and fundamentals of TPS in terms of the just in time (JIT) principle and automobile manufacturing technology, which has contributed to the simultaneous achievement of QCD at Toyota. In Chapter Three, the author asserts the necessity for the evolution of manufacturing in order to deal with the management issues currently facing Japanese manufacturers. Therefore, in this chapter, the author establishes an advanced TPS and its effectiveness of strategic development, surpassing JIT. In Chapter Four, the author develops an advanced TPS for an automobile manufacturing strategy to expand this strategy throughout Japan and overseas. Safety Analysis to Strengthen Toyota Automobile Manufacturing is the topic of Part II. Todays management challenge is to provide excellent QCD products ahead of competitors through market creating activities. In the implementation stage, strategic QCD studies are needed to strengthen core technologies, and to have them mutually linked as a whole. Therefore, the author develops the safety analysis utilizing a statistical science known as the Science of SQC: The New Quality Control Principle for the strengthening of the business and manufacturing processes. Chapters Five Seven discuss and demonstrate the effectiveness of the following as the driving force in developing advanced TPS: Realizing high quality manufacturing, strengthening new manufacturing management technology, and creating an SCM strategy for developing QCD studies of Japan and overseas. In Part III, the author discusses and demonstrates the future directions for Toyotas manufacturing strategy. Focusing on a concrete target, the author reconsiders new management tasks foreseen for the advanced manufacturing companies, shifting to expanding global production. Based on the focus of Parts I and II, the author asserts the profitability (justification and validity) for re-progress in automobile manufacturing in order to deal with the management issues currently facing Japanese manufacturers. In Chapter Eight, as an oversea production strategy, the author propagates an "expanding new integrated production model" to developing countries and discusses the necessity for the global deployment. In Chapter Nine, the author shows and demonstrates the effectiveness of new production progress for re-strengthening global production. In Chapter Ten, the author provides an overall conclusion of the topics covered in this book.