Om Toyota

The Toyota Production System (TPS) is an integrated socio-technical system,
developed by Toyota, that comprises its management philosophy and practices.

The TPS is a management system that organizes manufacturing and logistics for
the automobile manufacturer, including interaction with suppliers and
customers. The system is a major precursor of the more generic "lean
manufacturing". Taiichi Ohno and Eiji Toyoda, Japanese industrial engineers,
developed the system between 1948 and 1975.
Originally called "just-in-time production", it builds on the approach created by
the founder of Toyota, Sakichi Toyoda, his son Kiichiro Toyoda, and the
engineer Taiichi Ohno.
Workforce: Toyota Kirloskar Motor (TKM), based in Bidadi near Bengaluru,

employs thousands across two main plants in the area. The first plant, producing
models like the Innova and Fortuner, has a capacity of 132,000 units annually,
while the second plant, manufacturing vehicles like the Camry Hybrid and
Hilux, has a capacity of 210,000 units. Together, these plants generate
significant employment, and the recent announcement of a third plant in Bidadi
will add an additional 2,000 jobs, underscoring Toyota’s expanding presence in
Karnataka. Toyota also supports workforce development through initiatives like
the Toyota Technical Training Institute (TTTI), which has trained over 1,000
students locally and 12,000 across India
Product Development Process (PDP) –
 Customer and Market Analysis in India
 Conduct extensive research to understand the needs of Indian customers,
focusing on fuel efficiency, affordability, and durability, given the local
driving conditions.
 Concept Localization and Development
 Tailor global concepts to fit Indian conditions, such as adapting materials
to withstand varied climates and designing for congested urban spaces.
 Prototype Testing for Local Conditions
 Develop and test prototypes specifically for Indian roads, focusing on
factors like fuel efficiency, ease of maintenance, and durability under
challenging conditions.
 Engineering and Supplier Integration
 Collaborate with local suppliers to ensure parts and components are
sourced locally, reducing costs and fostering stronger supplier
partnerships.
 Production Preparation with Localization
 Modify production lines to accommodate models adapted for India,
utilizing lean processes to maximize space and resources while ensuring
high quality.
 Pilot Testing under Real-World Conditions
 Conduct pilot production runs and field tests to ensure the product
performs well under Indian driving and environmental conditions.
 Launch and After-Sales Feedback
 Collect post-launch feedback in Bangalore and nationwide, using it to
refine future models and improve production processes.
Here’s a flowchart representing the Product Development Process (PDP) for
the Toyota Production System (TPS)
1. Customer Need Identification &

Market Research
2. Concept Development &
Localization
3. Prototype Development &
Testing
4. Engineering Design & Validation
5. Production Preparation Process

(3P) 7 Supplier Collaboration
6. Pilot Production & Real -World
Testing
7. Full-Scale Production & Launch
8. Post-Launch Evaluation &

Improvement
Design thinking
Integrating design thinking into the Toyota Production System (TPS) creates a
customer-focused and efficient production process. It starts with Empathize,
gathering customer insights to inform improvements. In Define, specific
production issues are identified, aligning with TPS’s focus on reducing waste
and creating value. During Ideate, team members generate solutions, fostering
innovation through Kaizen. Prototype involves testing changes on a small scale
using the PDCA cycle, while Test monitors for improvements in quality and
efficiency, reflecting TPS’s Jidoka principle. Finally, Implement and Scale rolls
out proven improvements system-wide, maintaining efficiency through just-in-
time production and standardized work.
Emphasize Define Ideate
Customer and define the specific

market needs needs that must be Generate deas for
analyze data and adressed in the reducing
conduct market production process waste ,improving
reseach to workflows and
understand enhancing
customer pain productivity
points
Prototype Test Implement &

scale
Build prototypes Test the prototype Once validated,

for different processes to scale the tested
aspects of measure process
production to test improvements in improvements
workflow quality , speed, across the
improvements and cost producton system
small batch testing Gather feedback
and plan-do- and refine the
check-act (PDCA) process to
cycle. enhance outcomes

Om Toyota

Uploaded by

Copyright:

Available Formats

Om Toyota

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Om Toyota

Uploaded by

Copyright:

Available Formats

The Toyota Production System (TPS) is an integrated socio-technical system,

developed by Toyota, that comprises its management philosophy and practices.

Workforce: Toyota Kirloskar Motor (TKM), based in Bidadi near Bengaluru,

1. Customer Need Identification &

4. Engineering Design & Validation

5. Production Preparation Process

7. Full-Scale Production & Launch

8. Post-Launch Evaluation &

Customer and define the specific

Prototype Test Implement &

Build prototypes Test the prototype Once validated,

You might also like

Pfad - The Proxy pFad of © 2024 Garber Painting. All rights reserved.