Toyota Production System

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Blog Posts About Toyota Production System

Here is a list of all of the blog posts on Kanban Zone that discuss Toyota production system.

5 Big Companies Using Kanban for Business Operations

Kanban is a process-based management system that helps teams visualize their workflows and improve communication. Many giant companies using Kanban have enabled their teams to work more efficiently. Whether you are into fashion, finance, tech, or manufacturing business, you can opt for Kanban to manage your team's workflow and improve their productivity. Are you considering using Kanban for your business but not sure if it applies to your operations? To help you know what to expect from this workflow management tool, let's dive into the world of business and see how big companies using Kanban manage their teams' workflow effectively. Companies Using the Kanban System for Business Operations Here is a list of 5 big companies that are using Kanban boards: 1. Toyota Toyota is a multinational company that manufactures cars, trucks, and SUVs. They have more than 338,000 employees worldwide. When it comes to managing its workflow, Toyota

By |2022-01-04T11:27:48-07:00January 4th, 2022|Kanban, Kanban Board, Process Flow, Toyota Production System|

Toyota Kata: What is it and How Can it Help You Continuously Improve?

Toyota Kata is a management philosophy that aims to help businesses continuously improve. It was developed by Taiichi Ohno, the father of the Toyota Production System. As defined by its name, “Kata,” it means continuous improvement. It's not exactly what they teach in school. But, it has been proven time and again to work for organizations of all sizes.  What is Kata? Kata is a structural process that is used to help individuals understand a model of an internal process. It is not a fixed pattern but can be modified and rewritten as required depending on the business objectives. Kata was developed by Taiichi Ohno, father of the Toyota Production System (TPS). He wanted to instill in his workers how important it is for them to improve their manufacturing system or kaizen continuously, as they call it. This philosophy was so ingrained with all employees from day one that

By |2022-04-25T08:57:32-07:00December 8th, 2021|Kaizen, Lean Thinking, Toyota Production System|

5 Benefits of Kanban for Toyota Production System

The Toyota Production System (TPS) is often referred to as creating lean manufacturing alongside several other companies like Bell System and General Motors Corporation. The initial principles were created by its founder Sakichi Toyoda in Japan during 1938. Even though this system was initially developed in Japan, it has spread worldwide and has become one of the largest influences on modern production systems. Nowadays, along with TPS, Kanban has also started playing an essential role in helping organizations manage their production processes. In fact, many businesses nowadays are realizing the many benefits of using Kanban for Toyota production system implementation. The Vision & Philosophy of TPS Toyota's vision is "to be the best automaker in the world." A large part of this vision comes from their philosophy, which can accurately be described as an ideal towards perfection or the philosophy of continuous improvement. They have a very competitive drive

By |2021-12-08T13:05:07-07:00October 15th, 2021|Kanban, Kanban Board, Kanban Card, Toyota Production System|

5 Benefits of Setting Up an Andon System

We can thank the pioneers of the Japanese manufacturing industry for their relentless pursuit of efficiency and quality. Their innate drive towards high levels of quality and zero waste has paved the way for the birth of the Toyota Production System and Lean Manufacturing. And up to this day, we see these concepts and practices applied in businesses worldwide. One of the thirteen pillars of the Toyota Production System is called andon. Let’s explore how an andon system can help you improve quality in your workflow and why you should set up one.  What is andon? An andon system is a tool that is used to signal when something is wrong in a production process. In Japanese, the term andon is translated to “light” or “lamp.” The idea for an andon system in a production line is that it lights up to alert workers that an anomaly has occurred

By |2021-08-30T02:52:51-07:00June 24th, 2021|Toyota Production System|

The Toyota 3M Model: Identifying Wastes in Your Processes

The Toyota 3M model is an age-old concept that remains relevant to this day. Many manufacturing concepts and strategies are influenced by the Toyota 3M Model. It has helped reframe the mindset of business leaders on how they manage and eliminate wastes in their processes. Companies often look at how to generate more revenue by creating new products or revenue streams. But with the Lean methodology and the use of the 3M model, companies have learned another way to improve their revenue. Identifying wastes has been proven to help companies create more sustainable processes that support their revenue-generating activities while optimizing costs. Let’s explore what the Toyota 3M model is and how you can start creating a leaner process for your business. What is Muda, Mura and Muri? The “3M” in the Toyota 3M Model stands for muda, mura, and muri. These three Japanese words translate to the following:

Lean Manufacturing Principles and Concepts You Should Know About

Companies constantly pursue strategies and techniques to gain a competitive advantage and continuously improve their business. Companies look for measures to keep their costs in check, increase their productivity, and improve profitability. One of the most popular concepts that have helped transform companies is lean manufacturing. Let’s explore how Lean manufacturing helps businesses take their game to a whole new level.  What is Lean Manufacturing? To understand Lean manufacturing, we need to talk about Lean thinking. Lean thinking is a methodology that focuses on optimizing business processes through waste elimination, hence the term, Lean. Lean manufacturing is rooted in the Lean thinking methodology that started in the automobile industry. Its beginnings started with Henry Ford and his relentless pursuit against waste and inefficiency. He introduced various techniques that helped his employees work smarter. While Ford’s methods worked well to introduce standardization, it didn’t account for handling variation. This is

By |2022-04-25T08:52:08-07:00February 9th, 2021|Kaizen, Kanban, Lean Thinking, Process Flow, Toyota Production System|

Become a Better Manager with the Genchi Genbutsu Principle

Becoming a better manager isn’t something that happens instantly. It’s a process that takes experience and time. One thing that will fast track your journey to becoming a better manager is your ability to spot improvement opportunities and solve problems. I believe that working on any problem or improvement opportunity starts with data gathering and proper observation. It is the merging of data and experience that will arm managers to make better decisions for their teams and the company. This is where the genchi genbutsu principle comes in handy for those who want to become better managers.  What is the Genchi Genbutsu Principle? Genchi genbutsu is one of the thirteen pillars of the Toyota Production System. The closest English translation of the Japanese term genchi genbutsu is “actual location, actual thing.” Toyota brought a whole new meaning to this set of words and gave birth to a principle which

By |2022-04-25T08:59:27-07:00January 26th, 2021|Project Management, Toyota Production System|

Improve Your Decision Making with the Nemawashi Concept

It’s very common to see traditional managers call the shots when it comes to business decisions. This scenario is more prominent in Western companies and we see managers, executives, and founders try to figure out everything on their own. Employees are most often on the receiving end of information and instruction.  But more companies are changing the way they make business decisions. This makes them more engaged in their work. Not only does this create a more engaged workforce, but it helps businesses generate more ideas, refine, and implement them faster.  This switch from a top-down to a bottom-up decision-making process isn’t a 21st-century concept. Travel to the east and dial back to the late 1940s and we see this process happening in the floors of automobile giant, Toyota. The Toyota Production System was born with thirteen pillars including the nemawashi concept which describes how those on the ground

By |2020-12-16T08:25:05-07:00December 16th, 2020|General, Toyota Production System|

What is Inventory Kanban and How to Use It

The origins of Kanban dates back to the late 1940s when automobile manufacturing giant Toyota started the Toyota Production System (TPS). Toyota knew that for them to reach the top, they’d have to improve from within. The TPS was their way of organizing their end-to-end operations by optimizing human and machine capabilities and cost-reduction through the elimination of waste. This revolutionary system has become the DNA of Toyota and has been adopted by many other manufacturing companies since then. It has also influenced other management and product development methodologies we know today.  The Toyota Production System was also called Just-In-Time (JIT) Production. JIT is one of the main pillars of the TPS which was central to how materials and inventory moved and flowed throughout the Toyota production floor. JIT’s concept was to produce products when they are needed and in the quantity needed. With this, Toyota needed a way

What is Lean Agile Project Management?

Much is demanded of businesses in this modern world. Competition is tough. Consumer standards are high. And the market has never been as technology-driven as before. For businesses that want to thrive, they know that having a good product alone is insufficient. They need to look into how they make the product and run the company. A good product that sells needs a sustainable process that can back it up. These are processes that ensure quality, cost-savings, and maximum value are driven out of the pipeline. Most companies would turn to project management approaches to help them get these embedded in their processes. Two of the most popular methodologies businesses turn to is Lean and Agile project management. But an increasing trend we see is how these two methodologies are being combined. Companies turn to Agile Lean project management to solidify their businesses. But first, let’s take a look