PRODUCTION SYSTEM

PRODUCTION SYSTEM

 Manufacturing subsystem that includes all functions

required to design, produce, distribute, and service a

manufactured product.
TOYOTA PRODUCTION SYSTEM

 Is an integrated socio-technical system, developed

by Toyota, that comprises its management

philosophy and practices.

2 Main Pillar of TPS

1. JIT (JUST IN TIME)

2. JIDOKA

The Base of TPS

1. Heijunka

2. Kaizen
Pillar- JIT (JUST IN TIME)

 Produced according to what needed, when needed

and how much needed.

 Strategy to improve return on investment by

reducing inventory and associated cost.

 The process is driven by Kanban concept.

Kanban

Is a scheduling system for lean manufacturing and just-in-

time manufacturing (JIT). Taiichi Ohno, an industrial

engineer at Toyota,
Pillar- Jidoka
 a term used in Lean manufacturing meaning "automation

with a human touch.“

 highlights the causes of problems because work stops

immediately when a problem first occurs.

Toyota Production System which applies the following
four principles:
 Detect the abnormality.
 Stop.
 Fix or correct the immediate condition.
 Investigate the root cause and install a
countermeasure.
Base- Heijunka

 is a Japanese word that means “leveling.” When

implemented correctly

 helps organizations meet demand while reducing

while reducing wastes in production and interpersonal

processes.
Base- KAIZEN

 Also known as continuous improvement, is a long-

term approach to work that systematically seeks to

achieve small, incremental changes in processes in

order to improve efficiency and quality.

PRODUCTION, PLANNING AND CONTROL
Production

 The processes and methods used to transform

tangible inputs and intangible inputs into goods or

services.
Planning

 Is the process of thinking about the activities

required to achieve a desired goal.

Control
 The act of controlling something or someone
 Production Planning and Control

 Production planning and control deals with

the basic concepts of what to produce, when
to produce, how much to produce, and
involves taking a long-term view at overall
production planning
 Planning

Routing
Production
Planning
Scheduling

Loading
PPC
Dispatching

Following
Production up
Control
Inspection

Corrective
 Production Planning
Objectives
 To ensure right quantity and quality of raw material,
equipment, etc. are available during times of
production.
 To ensure capacity utilization is in tune with forecast
demand at all time.
 Planning
Objectives
 defined as the technique of foreseeing every step in
a long series of separate operations,
 each step is need to be taken at the right time and in
the right place and each operation need to be
performed in maximum efficiency.
 Routing
Objectives
 The main aim of routing is to determine the
best and cheapest sequence of operations
and to ensure that this sequence is strictly
followed
 Scheduling
Objectives
 It means working out of time that
should be required to perform each
operation
 Loading
Objectives
 execution of the schedule plan
 So loading determines who will do the
work, as routing determines where and
scheduling determines when it shall be
done.
 Production Control
 Production control works to monitor a
particular project or operation
 Production is structured according to
demand forecasts.
 Dispatching
 Dispatching involves issue of
production orders for starting
the operations.
 Follow up
 Ensuring that the productive
operations are taking place in
accordance with the plans.
 Inspection
 An inspection determines if the material
or item is in proper quantity and
condition, and if it conforms to the
applicable or specified requirements.
 Corrective Measure

 Intended to improve a situation

 Techniques are intended to put
right something that is wrong.
 Types of Production (Manufacturing) Systems

Job Order Production

Characterized by low volume and high variety of products.

(e.g Large engines, Bridge, Ships)

Batch Production

It is a Short Production runs and frequent changes in set up