Toyota Production System

A production system which is steeped in the philosophy of "the complete elimination of all waste" imbuing all aspects of production in pursuit of the most efficient methods.
Toyota Motor Corporation's vehicle production system is a way of "making things" that is sometimes referred to as a "lean manufacturing system" or a "Just-in-Time (JIT) system," and has come to be well known and studied worldwide. This production control system has been established based on many years of continuous improvements, with the objective of "making the vehicles ordered by customers in the quickest and most efficient way, in order to deliver the vehicles as quickly as possible." The Toyota Production System (TPS) was established based on two concepts: The first is called "jidoka" (which can be loosely translated as "automation with a human touch") which means that when a problem occurs, the equipment stops immediately, preventing defective products from being produced; The second is the concept of "Just-in-Time," in which each process produces only what is needed by the next process in a continuous flow. Based on the basic philosophies of jidoka and Just-in-Time, the TPS can efficiently and quickly produce vehicles of sound quality, one at a time, that fully satisfy customer requirements.

TPS Concept(Toyota production system)

Jidoka Highlighting/visualization of problems
-Quality must be built in during the manufacturing process!If equipment malfunction or a defective part is discovered, the affected machine automatically stops, and operators cease production and correct the problem. For the Just-in-Time system to function, all of the parts that are made and supplied must meet predetermined quality standards. This is Producing quality products efficiently through the complete elimination of waste, inconsistencies, and unreasonable requirements on the production line. In order to deliver a vehicle ordered by a customer as quickly as possible, the vehicle is efficiently built within the shortest possible period of time by adhering to the following:

Just-in-Time Productivity improvement

- Making only "what is needed, when it is needed, and in the amount needed!"

achieved through jidoka. 1. Jidoka means that a machine safely stops when the normal processing is completed. It also means that, should a quality / equipment problem arise, the machine detects the problem on its own and stops, preventing defective products from being produced. As a result, only products satisfying quality standards will be passed on to the following processes on the production line. 2. Since a machine automatically stops when processing is completed or when a problem arises and is communicated via the "andon" (problem display board), operators can confidently continue performing work at another machine, as well as easily identify the problem's cause to prevent its recurrence. This means that each operator can be in charge of many machines, resulting in higher productivity, while continuous improvements lead to greater processing capacity.

1. When a vehicle order is received, a production instruction must be issued to the beginning of the vehicle production line as soon as possible. 2. The assembly line must be stocked with required number of all needed parts so that any type of ordered vehicle can be assembled. 3. The assembly line must replace the parts used by retrieving the same number of parts from the partsproducing process (the preceding process). 4. The preceding process must be stocked with small numbers of all types of parts and produce only the numbers of parts that were retrieved by an operator from the next process.

Ford Production SYSY

January 1995, Ford employed a company-wide reengineering initiative called Ford 2000. One of the major objectives of Ford 2000 program was to develop and implement a new manufacturing system called the Ford Production System (FPS). According to Ford's website, "The vision of FPS is a lean, flexible and disciplined common production system, defined by a set of principles and processes, that employs groups of capable and empowered people, learning and working safely together, in the production and delivery of products that consistently exceed customers' expectations in quality, cost and time." FPS was an attempt by Ford to transform itself from mass production system to lean manufacturing system...
Lean Manufacturing in Practice

Lean manufacturing aimed at bringing together human, material and mechanical resources at the right time and place to accomplish a task. It strived to eliminate every kind of waste including wastage of time, labor, scrap material, defective parts, etc. There were several instances in which the company achieved massive productivity improvements through lean manufacturing techniques...
Production Systems of the Future

By 2003, all the plants of Ford had adopted FPS in their operations. It was estimated that after the implementation of FPS, Ford had achieved savings to the tune of $500 mn per year. The personnel at the plants also received web-based training while best practices were identified and shared between the plants. By mid-2003, Ford was in the process of standardizing manufacturing operations across all its plants globally. The company planned to implement standard operating procedures and uniform plant layouts...

Maruthi System
Production Management System Click here to know more

Challenge 50 helped us improve our plant productivity by 46 per cent in three years and cost & quality improved by 30 per cent. Moving Production PMS PMS is is a ahead, Management strategy to the next System achieve (PMS) target was was the to next sustain bold step through this in this momentum. direction. approach.

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is people driven and ensures involvement of all levels ( Managers, Executives, Supervisors ) ensures ownership brings in standardization of systems & processes ensures Sustainability fourth phase of implementation and the results have been overwhelming.

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Excellence through participative approach PMS is a bottoms-up approach where people of the work area are encouraged to give solutions to the problems at their end. It is implemented across levels. This motivates the operator and ensures his ownership all through the solution finding process. The concept ensures participation and error free communication. The result is clarity of content, better understanding and openness towards feedback. These values make PMS a sustainable system. Clarity of the Role One of the aspect that have bothered hierarchical structures is the clarity of the roles and responsibility across strata. Clarity on what is expected out of a supervisor, a manager or a technician at the shop floor has brought in structure and standardization to production management at Maruti. The result is that job duplication is eliminated and no man-hours are lost in understanding what each person is expected to do. The outcome of such clearly defined roles is increased efficiency of operations.

Bringing in Standardization Through such people participation, PMS has brought in standardization that eliminates any scope of confusion at shop floor. A visual consistency across the manufacturing facilities is notable. Bins and trolleys are earmarked for tools and components. Pictorial charts explaining processes and procedures are pasted at convenient and strategic points helping shop floor employees understand various mechanisms with ease. Wherever possible a colour coding control or visual control is followed to eliminate operator errors arising out of language constraints. This helps in clear distinction of different model and its components. All around Gains These processes have led to many operational improvements that have saved cost and time. At the same time these have brought in operational ease and a defined activity flow and sequence. Marching ahead towards the goal of selling a million vehicles by 2010, PMS will lead the production team towards greater enhanced productivity with perfection.

Maintenance Preventive
A preventative maintenance technician performs routine maintenance on equipment and systems to keep them in working order. This includes the completion of scheduled maintenance within recommended time frames as well as regular inspections of systems to identify issues that may need to be addressed. This work may require certification and licensure, depending on the types of systems the technician works on. There are a number of paths to pursue to become a preventative maintenance technician. Transit companies like airlines, city bus systems, and trucking companies use such technicians to keep their equipment running, as do factories and large buildings with extensive systems like heating and cooling. Scheduled maintenance needs to be performed on time, and these technicians can also regularly evaluate engines and other components for signs of wear and other concerns. If more maintenance is necessary, they can perform it before it necessitates emergency repairs. Part of the goal of a preventative maintenance technician is to prevent an emergency that might damage equipment, cause injuries, or create time delays. This work also requires keeping detailed logs on equipment. The technician must record all maintenance activity, including the date and specifics. This information can be useful for reference and may be necessary in the event of a legal problem. Technicians can also record serial numbers for parts they install along with other data to verify their activities and create a clear paper trail through the maintenance department. These logs are usually kept in a secure area to make sure they will be available when needed. The scope of duties for a preventative maintenance technician can vary. More qualified personnel may have more responsibilities, while trainees and less qualified technicians may have fewer activities on the job. Employers may set policies to determine which kinds of tasks are appropriate with various levels of training. Technicians are typically supervised by someone with a high degree of training, who is capable of monitoring maintenance activities and performing them, if necessary. Training to become a preventative maintenance technician can involve attending a technical or trade school, or learning on the job. Some technicians belong to professional organizations that may set standards for admittance. These organizations administer tests and may also require proof of a set number of years of training and experience. Certification can increase employability in some sectors and may also allow a technician to negotiate better wages and benefits. It can be especially important for technicians who want to rise to supervisory positions.

Industrial Maintenance
Industrial maintenance usually refers to the repair and upkeep of the different types of equipment and machines used in an industrial setting. The basics of industrial maintenance may be broken down into the following five categories: general knowledge, mechanical knowledge, electrical knowledge, welding knowledge, and preventative maintenance. According to this wide variety of areas of expertise, industrial maintenance technicians usually are multi-skilled individuals, proficient in many tasks. Industrial maintenance also involves a great degree of problem solving skill. Identifying the problem alongside the best and safest means of resolving the difficulty typically are integral parts of the industrial maintenance process. The general knowledge usually required in industrial maintenance is an understanding of tools, blueprint reading, and safety. The correct tools and the comprehension of how to use them can be crucial for fixing

potential machinery problems. Blueprint reading enables the industrial maintenance technician to understand how a particular machine works. Safety is also a pivotal aspect of maintenance, as most industrial machines can be considered dangerous. It usually is important for the technician to maintain his or her own safety, as well as those of the workers using the machinery. Mechanical knowledge of how machines function may include a familiarity with concepts such as mechanical power transmission, fluid power, piping systems, pumps, and compressors. Since any number of mechanical parts can make up a piece of machinery, industrial maintenance typically requires the knowledge of how machines function in general. A familiarity with wiring, transformers and basic industrial electronics allows for the repairing of machines experiencing problems with power supplies. The knowledge of welding techniques, such as arc welding and gas welding, also can be necessary to solve a mechanical problem. Industrial maintenance technicians may be on-site employees or can be privately contracted in the event of required maintenance. Many manufacturers of machinery offer industrial maintenance for their respective products in the form of service technicians. Service technicians employed by these firms generally are experts on the machinery produced by these companies and are familiar with how to fix any possible problems. The field of industrial maintenance does not involve just the repair of already existing malfunctions. Preventative maintenance typically is an important part of the field. As modern industrial machinery is expensive, it is usually important for businesses to ensure the upkeep of their investment. Preventative maintenance also may help ensure that machinery is safe, which can assist in maintaining the health of workers and equipment users.

Types of Maintenance
1. Breakdown maintenance
It means that people waits until equipment fails and repair it. Such a thing could be used when the equipment failure does not significantly affect the operation or production or generate any significant loss other than repair cost.

2. Preventive maintenance ( 1951 )

It is a daily maintenance ( cleaning, inspection, oiling and re-tightening ), design to retain the healthy condition of equipment and prevent failure through the prevention of deterioration, periodic inspection or equipment condition diagnosis, to measure deterioration. It is further divided into periodic maintenance and predictive maintenance. Just like human life is extended by preventive medicine, the equipment service life can be prolonged by doing preventive maintenance.

2a. Periodic maintenance ( Time based maintenance - TBM)

Time based maintenance consists of periodically inspecting, servicing and cleaning equipment and replacing parts to prevent sudden failure and process problems.

2b. Predictive maintenance

This is a method in which the service life of important part is predicted based on inspection or diagnosis, in order to use the parts to the limit of their service life. Compared to periodic maintenance, predictive maintenance is condition based maintenance. It manages trend values, by measuring and analyzing data about deterioration and employs a surveillance system, designed to monitor conditions through an on-line system.

3. Corrective maintenance ( 1957 )

It improves equipment and its components so that preventive maintenance can be carried out reliably. Equipment with design weakness must be redesigned to improve reliability or improving maintainability

4. Maintenance prevention ( 1960 )

It indicates the design of a new equipment. Weakness of current machines are sufficiently studied ( on site information leading to failure prevention, easier maintenance and prevents of defects, safety and ease of manufacturing ) and are incorporated before commissioning a new equipment.