TPS in Britain to build the Toyota Auris and Avensis models
Autor: Lauro Morio Kamimura | Publicado: 2016-08-22T12:54:00-07:00


Toyota Production System is
the blueprint for modern manufacturing, and is employed in Britain to build the&nbsp;Toyota Auris&nbsp;and&nbsp;Avensis&nbsp;models. Here, we take a look at the thirteen
philosophies that underpin it.

Konnyaku Stone



The Konnyaku Stone is
used to smooth unpainted body panels and remove imperfections. The size of a
fist, and made of gritty resins; the stone is known as the ‘devil’s tongue’.
Brushing the stone across the surface of a panel smooths the metal so that it
is ready for painting.

Poka-Yoke

<!--[if gte vml 1]><v:shape
 id="Imagem_x0020_12" o:spid="_x0000_i1036" type="#_x0000_t75" alt="Poka Yoke gallery"
 href="http://blog.toyota.co.uk/wp-content/uploads/2013/05/Poka-Yoke-gallery.jpg"
 style='width:442.5pt;height:249.75pt;visibility:visible;mso-wrap-style:square'
 o:button="t">
 
 <v:imagedata src="file:///C:\Users\Lauro\AppData\Local\Temp\msohtmlclip1\01\clip_image002.jpg"
  o:title="Poka Yoke gallery"/>
<![endif]--><!--[if !vml]--><!--[endif]-->

Put simply, Poka-Yoke
means to avoid (yokeru) mistakes (poka). The Toyota Production System employs
devices that automatically stop the line if there is an error.





Hansei

<!--[if gte vml 1]><v:shape
 id="Imagem_x0020_11" o:spid="_x0000_i1035" type="#_x0000_t75" alt="Hansei gallery"
 href="http://blog.toyota.co.uk/wp-content/uploads/2013/05/Hansei-gallery.jpg"
 style='width:442.5pt;height:249.75pt;visibility:visible;mso-wrap-style:square'
 o:button="t">
 
 <v:imagedata src="file:///C:\Users\Lauro\AppData\Local\Temp\msohtmlclip1\01\clip_image003.jpg"
  o:title="Hansei gallery"/>
<![endif]--><!--[if !vml]--><!--[endif]-->

Hansei is the process
of recognising and learning from mistakes, in order to prevent them from
occurring again. Toyota hosts hansei-kai meetings, in which failures
experienced during the production process (if there were any), are reflected
on, and future prevention plans put in place.





Andon

<!--[if gte vml 1]><v:shape
 id="Imagem_x0020_10" o:spid="_x0000_i1034" type="#_x0000_t75" alt="Andon gallery"
 href="http://blog.toyota.co.uk/wp-content/uploads/2013/05/Andon-gallery.jpg"
 style='width:442.5pt;height:249.75pt;visibility:visible;mso-wrap-style:square'
 o:button="t">
 
 <v:imagedata src="file:///C:\Users\Lauro\AppData\Local\Temp\msohtmlclip1\01\clip_image004.jpg"
  o:title="Andon gallery"/>
<![endif]--><!--[if !vml]--><!--[endif]-->

Andon is a visual aid
that highlights where action is required. Usually activated by a button or
pull-chord; production is automatically halted&nbsp;when a member of staff
pulls it.&nbsp;







Jidoka&nbsp;

<!--[if gte vml 1]><v:shape
 id="Imagem_x0020_9" o:spid="_x0000_i1033" type="#_x0000_t75" alt="Jidoka gallery"
 href="http://blog.toyota.co.uk/wp-content/uploads/2013/05/Jidoka-gallery.jpg"
 style='width:442.5pt;height:249.75pt;visibility:visible;mso-wrap-style:square'
 o:button="t">
 
 <v:imagedata src="file:///C:\Users\Lauro\AppData\Local\Temp\msohtmlclip1\01\clip_image005.jpg"
  o:title="Jidoka gallery"/>
<![endif]--><!--[if !vml]--><!--[endif]-->

Designing equipment
to detect problems and stop automatically when required are fundemental to
Jidoka. Toyota Production System operators can stop production the moment they
spy something untoward, preventing the wasted production of defective items.



Just-In-Time

<!--[if gte vml 1]><v:shape
 id="Imagem_x0020_8" o:spid="_x0000_i1032" type="#_x0000_t75" alt="just-in-time"
 href="http://blog.toyota.co.uk/wp-content/uploads/2013/05/JIT.jpg" style='width:442.5pt;
 height:294.75pt;visibility:visible;mso-wrap-style:square' o:button="t">
 
 <v:imagedata src="file:///C:\Users\Lauro\AppData\Local\Temp\msohtmlclip1\01\clip_image006.jpg"
  o:title="just-in-time"/>
<![endif]--><!--[if !vml]--><!--[endif]-->

A cornerstone of
modern manufacturing, just-in-time production was pioneered by Toyota. It
consists of a&nbsp;A ‘pull’ system (as opposed to push) that provides the
different processes in the assembly sequence with only the kinds and quantities
of items that they need and only when it needs them. It allows cars to be built
to order for optimal efficiency and financial management.

Heijunka

<!--[if gte vml 1]><v:shape
 id="Imagem_x0020_7" o:spid="_x0000_i1031" type="#_x0000_t75" alt="Heijunka"
 href="http://blog.toyota.co.uk/wp-content/uploads/2013/05/Heijunka.jpg"
 style='width:442.5pt;height:295.5pt;visibility:visible;mso-wrap-style:square'
 o:button="t">
 
 <v:imagedata src="file:///C:\Users\Lauro\AppData\Local\Temp\msohtmlclip1\01\clip_image007.jpg"
  o:title="Heijunka"/>
<![endif]--><!--[if !vml]--><!--[endif]-->

Heijunka means having
the correct number of parts required to build a specific number of cars for the
smoothest possible production process.

Heijunka&nbsp;is
important when sequencing production. For instance, if a factory was required
to send batches of high spec cars down its assembly line at the same time,
workers would be required&nbsp;to manage additional build tasks not present in
less well-equipped cars.&nbsp;Heijunka&nbsp;solves the problem by assembling a
mix of models within each batch.

Kaizen

<!--[if gte vml 1]><v:shape
 id="Imagem_x0020_6" o:spid="_x0000_i1030" type="#_x0000_t75" alt="Kaizen gallery"
 href="http://blog.toyota.co.uk/wp-content/uploads/2013/05/Kaizen-gallery.jpg"
 style='width:442.5pt;height:249.75pt;visibility:visible;mso-wrap-style:square'
 o:button="t">
 
 <v:imagedata src="file:///C:\Users\Lauro\AppData\Local\Temp\msohtmlclip1\01\clip_image008.jpg"
  o:title="Kaizen gallery"/>
<![endif]--><!--[if !vml]--><!--[endif]-->

Kaizen is at the
heart&nbsp;of The Toyota Production System. It serves as a mantra for
continuous improvement; the effects of which are far-reaching, from waste
elimination to efficiency optimisation.&nbsp;Kaizen gives voice to the
workforce, empowering individuals to identify areas for improvement and suggest
practical solutions.

Genchi Genbutsu

<!--[if gte vml 1]><v:shape
 id="Imagem_x0020_5" o:spid="_x0000_i1029" type="#_x0000_t75" alt="Genchi Genbutsu gallery"
 href="http://blog.toyota.co.uk/wp-content/uploads/2013/05/Genchi-Genbutsu-gallery.jpg"
 style='width:442.5pt;height:249.75pt;visibility:visible;mso-wrap-style:square'
 o:button="t">
 
 <v:imagedata src="file:///C:\Users\Lauro\AppData\Local\Temp\msohtmlclip1\01\clip_image009.jpg"
  o:title="Genchi Genbutsu gallery"/>
<![endif]--><!--[if !vml]--><!--[endif]-->

Genchi Genbutsu is
the idea that the best way to solve a problem is to see it for yourself. In the
Toyota Production System, managers are present on the factory floor; this
immersive approach means they fully understand the working environment and processes,
and can advise the best possible solution when a problem arises.

Nemawashi

<!--[if gte vml 1]><v:shape
 id="Imagem_x0020_4" o:spid="_x0000_i1028" type="#_x0000_t75" alt="Nemawashi gallery"
 href="http://blog.toyota.co.uk/wp-content/uploads/2013/05/Nemawashi-gallery.jpg"
 style='width:442.5pt;height:249.75pt;visibility:visible;mso-wrap-style:square'
 o:button="t">
 
 <v:imagedata src="file:///C:\Users\Lauro\AppData\Local\Temp\msohtmlclip1\01\clip_image010.jpg"
  o:title="Nemawashi gallery"/>
<![endif]--><!--[if !vml]--><!--[endif]-->

Decisions shouldn’t
be dictated by individuals, they should be made as a team – this the thinking
behind Nemawashi.&nbsp;In the Toyota Production System, information is shared
openly with employees, in order involve them in decision-making processes and
allow them to voice their opinions.







Kanban

<!--[if gte vml 1]><v:shape
 id="Imagem_x0020_3" o:spid="_x0000_i1027" type="#_x0000_t75" alt="Kanban gallery"
 href="http://blog.toyota.co.uk/wp-content/uploads/2013/05/Kanban-gallery.jpg"
 style='width:442.5pt;height:249.75pt;visibility:visible;mso-wrap-style:square'
 o:button="t">
 
 <v:imagedata src="file:///C:\Users\Lauro\AppData\Local\Temp\msohtmlclip1\01\clip_image011.jpg"
  o:title="Kanban gallery"/>
<![endif]--><!--[if !vml]--><!--[endif]-->

Immortalised as a
flashing signboard, Kanban is a&nbsp;system that conveys information between
processes and automatically orders parts as they are used up.&nbsp;Toyota has
six rules for the effective application of&nbsp;Kanban: 1) Never pass on defective&nbsp;products;
2) Take only what is needed; 3) Produce the exact quantity required; 4) Level
the production; 5) Fine-tune production; and 6) Stabilise and rationalise the
process.

Muda, Muri, Mura

<!--[if gte vml 1]><v:shape
 id="Imagem_x0020_2" o:spid="_x0000_i1026" type="#_x0000_t75" alt="Muri gallery"
 href="http://blog.toyota.co.uk/wp-content/uploads/2013/05/Muri-gallery.jpg"
 style='width:442.5pt;height:249.75pt;visibility:visible;mso-wrap-style:square'
 o:button="t">
 
 <v:imagedata src="file:///C:\Users\Lauro\AppData\Local\Temp\msohtmlclip1\01\clip_image012.jpg"
  o:title="Muri gallery"/>
<![endif]--><!--[if !vml]--><!--[endif]-->

Muda, Muri and Mura
work in tandem to eliminate waste. &nbsp;Muda actually means waste, but in the
context of the Toyota Production System, waste is defined as non-value-adding
activities such as over-processing. Muda divides waste up into seven
catergories: Transportation, inventory, motion, waiting, over-processing,
over-production, and defects.

Muri means to
overburden, and this is avoided by even distribution of production tasks in the
assembly processes.

Mura means
unevenness, which is eliminated in the Toyota Production System by training
workers&nbsp;to operate multiple machines, so that
there is cohesion between their operation.

Genba

<!--[if gte vml 1]><v:shape
 id="Imagem_x0020_1" o:spid="_x0000_i1025" type="#_x0000_t75" alt="Genba gallery"
 href="http://blog.toyota.co.uk/wp-content/uploads/2013/05/Genba-gallery.jpg"
 style='width:442.5pt;height:249.75pt;visibility:visible;mso-wrap-style:square'
 o:button="t">
 
 <v:imagedata src="file:///C:\Users\Lauro\AppData\Local\Temp\msohtmlclip1\01\clip_image013.jpg"
  o:title="Genba gallery"/>
<![endif]--><!--[if !vml]--><!--[endif]-->

Genba&nbsp;is the
physical place where work is done, and its&nbsp;philosophy is that all actions
and processes are as transparent as possible.&nbsp;Toyota team members regularly
conduct ‘Genba Walks’ on the factory floor,&nbsp;in order to identify areas where
potential improvements might be made, and to better understand the workload of
their colleagues.

A detailed glossary
of the Toyota Production System is available&nbsp;here.


By Eliott Farr