Toyota Production System

1. Front Matter

   Pages i-xvii

   PDF

2. Total System

   1. Front Matter

      Pages xix-xix

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   2. Total Framework of the Toyota Production System

      • Yasuhiro Monden

      Pages 1-14

3. Subsystems

   1. Front Matter

      Pages N1-N1

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   2. Adaptable Kanban System Maintains Just-In-Time Production

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      Pages 15-35

   3. Supplier Kanban and the Sequence Schedule Used by Suppliers

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      Pages 37-62

   4. Smoothed Production Helps Toyota Adapt to Demand Changes and Reduce Inventory

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      Pages 63-73

   5. The Information System Between Toyota, Its Dealers, and Parts Manufacturers

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      Pages 75-87

   6. Computer Control System in an Automobile Factory

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      Pages 89-103

   7. How Toyota Shortened Production Lead Time

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      Pages 105-120

   8. Reduction of Setup Time—Concepts and Techniques

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      Pages 121-129

   9. Practical Procedure for Reducing Setup Time

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      Pages 131-143

   10. Standard Operations Can Attain Balanced Production with Minimum Labor

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       Pages 145-158

   11. Machine Layout, Multi-Function Workers, and Job Rotation Help Realize Flexible Workshops

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       Pages 159-175

   12. Improvement Activities Help Reduce the Work Force and Increase Worker Morale

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       Pages 177-197

   13. 5S—Foundation for Improvements

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       Pages 199-219

   14. “Autonomous Defects Control” Assures Product Quality

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       Pages 221-238

   15. Functional Management to Promote Company-Wide Quality Control and Cost Management

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       Pages 239-251

4. Quantitative Techniques

   1. Front Matter

      Pages N3-N3

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   2. Sequencing Method for the Mixed-Model Assembly Line to Realize Smoothed Production

      • Yasuhiro Monden

      Pages 253-264

The Just-in-time (JIT) manufacturing system is an internal system in use by its founder, Toyota Motor Corporation, but it has taken on a new look. Toyota Production System, Second Edition systematically describes the changes that have occurred to the most efficient production system in use today. Since the publication of the first edition of this book in 1983, Toyota has integrated JIT with computer integrated manufacturing technology and a strategic informa­ tion system. The JIT goal of producing the necessary items in the necessary quantity at the necessary time is an internal driver of production and operations management. The addition of computer integrated technology (including expert systems by artificial intelligence) and information systems technology serve to further reduce costs, increase quality, and improve lead time. The new Toyota production system considers how to adapt production schedules to the demand changes in the marketplace while satisfying the goals of low cost, high quality, and timely delivery. The first edition of this book, Toyota Production System, published in 1983, is the basis for this book. It was translated into many languages including Spanish, Russian, Italian, Japanese, etc., and has played a definite role in inspiring production management systems throughout the world.

• Kanban
• Manufacturing
• Manufacturing System
• Master Planning
• numerical analysis
• production
• production management

• Institute of Socio-Economic Planning, University of Tsukuba, Tsukuba, Japan

  Yasuhiro Monden

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