1. Lean Manufacturing and the
Toyota Production System

2. What is Lean Manufacturing?
Lean is a set of tools that assist
in the identification & steady
elimination of waste (muda) , the
improvement of quality,
production time & cost reduction.

3. Goals of Lean
• Using less materials
• Requiring less investments
• Using less inventory
• Consuming less space
• Using less people

4. Toyota Production System - TPS
 Created by Taiichi Ohno
 The Toyota Production System,Beyond
Large-Scale Production

5. What is TPS?
“TPS is a production system which is a
quantity control system, based on a
foundation of quality, whose goal is cost
reductions & the means to reduce cost is
the absolute elimination of waste.”
-Ohno

6. 5 fold Definition of TPS
• Has a focus on quantity control to reduce cost
by eliminating waste.
• Is built on strong foundation of processes &
product quality.
• Is fully integrated.
• Is continually evolving.

7. • Is perpetuated by a strong healthy culture
that is managed consciously, continuously &
consistently.

8. 2 Pillars of the TPS
• Just in Time (J.I.T.)
• JIDOKA

9. Just in Time (J.I.T.)
The technique of supplying exactly the
right quantity at exactly the right time &
exactly the right location.

10. JIDOKA
Is a series of cultural & technical issues
regarding the use of machines and manpower
together, utilizing people for the unique tasks
they are able to perform & allow the machines
to self-regulate the quality. It uses:
poka-yoke = fool proofing the process
andons = visual displays such as light to
indicate process status

11. THANK YOU AND GOD BLESS
“Start by doing what's necessary;
then do what's possible;
and suddenly you are doing the impossible.”
-St. Francis of Assisi