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The American University in Cairo Mechanical Engineering Department Toyota Production System (TPS) Presented by: Doaa Abdel Azim Mohamed Abdel Motaleb Omar El Kholy. Outline. Taken from: http://www.gemba.com/uploadedImages/Picture5.png. Background:.

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Outline

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  1. The American University in CairoMechanical Engineering DepartmentToyota Production System (TPS)Presented by: Doaa Abdel AzimMohamed Abdel MotalebOmar El Kholy

  2. Outline Taken from: http://www.gemba.com/uploadedImages/Picture5.png

  3. Background: • Established in 1950s by the Japanese engineer Ohno. • Known as TPS in the 1970s. • It is targeting: Best cost, quality, delivery, empowering people, and minimizing wastes. http://www.optiprise.com/images/Taichii_Ohno_large.jpg

  4. Foundation: • Heijunka: • averages the daily production in order to have smooth production schedules. • averages both the volume and sequence of different model types on a mixed-model production line

  5. Foundation (cont.): • Standardized work: • organizing all jobs and creating an efficient production sequence. • Consists of three components: • Takt time: used to set the rate of production • Working Sequence and Standard sequence of operations in a single process • Standard in-process stock: The least amount of stock on hand that is needed for a process to be completed

  6. Foundation (cont.): • Kaizen • Monitoring quality of the product • Studying the work place • Ensuring the workplace safety to increase efficiency of the worker and the process.

  7. Pillars: • Just In Time: • Eliminates all steps required in production planning • produce the product in the exact time it is required to be completed (not before or after) • minimizes manufacturing wastes (storage, moving…etc)

  8. Pillars (Cont’d): • Components of JIT: • Takt time: to be able to deliver on time • Downstream Pull: customer is the one who “pulls” what he wants from the producer, thus allows the producer to minimize overproduction • One piece flow:one work piece should be moving between different operations within one work cell

  9. Pillars (Cont’d): Example of one piece flow (Taken from: http://www.mamtc.com/lean/building_onePiece.asp)

  10. Pillars (Cont’d): • Jidoka • Jidoka is a quality system built in the process. • concerned with the process of dealing with the faults which may take place during production. http://www.strategosinc.com/jidoka_1.htm

  11. Pillars (Cont’d): • Pakayoke: ”error proofing“ • Searches for the reason of the defect. • Create "error proofing" techniques.

  12. References: • Online, http://personal.ashland.edu/~rjacobs/m503jit.html, accessed 15 May 2005 • Online, http://www.gemba.com/resources.cfm?id=41#P, accessed 10 May 2005 • Online, http://www.mamtc.com/lean/building_onePiece.asp, accessed 18 May 2005 • Online, http://www.plant-maintenance.com/articles/tpm_intro.shtml, accessed 12 May 2005 • Online, http://www.strategosinc.com/takt_time.htm, accessed 10 May 2005 • Online, http://www.swmas.co.uk/Lean_Tools/Takt_Time.php, accessed 13 May 2005 • Online, http://www.toyota.co.jp/en/about_toyota/history/, accessed 5 may 2005 • Online, http://www.toyotageorgetown.com/terms.asp, accessed 7 May, 2005 • Online, http://www.gemba.com/consulting.cfm?id=144, accessed 8 May 2005 • Online, www.kybiz.com/lanereport/issues/november02/toyota.html, accessed 10 May 2005 • Online, www.strategosinc.com, accessed 19 May, 2005 • Online,www.toyotageorgetown.com/terms.asp, accessed 17 May 2005 • Online, www.vorne.com/solutions/learning_center/tps.htm, accessed 12 May, 2005

  13. Thank you very much Any Questions???

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