Toyota Production System An Integrated Approach to Just-In-Time
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
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Toyota Production System An Integrated Approach to Just-In-Time Second Edition
Yasuhiro Monden
Institute of Industrial Engineers®
CHAPMAN &. HALL London· Glasgow· New York· Tokyo · Melbourne· Madras
© 1994 Yasuhiro Monden
Softcover reprint of the hardcover 1st edition 1994 ISBN-13: 978-1-4615-9716-2
e-ISBN-13: 978-1-4615-9714-8
DOl: 10.1007/978-1-4615-9714-8
Contents Toyota Production System Japanese Tenns .......................................................... xi Foreword to the First Edition ............................................................................. xiii Preface ............................................... ...................................................... ............ xv Acknowledgments ............................................................................................... xvii PART
I
TOTAL SYSTEM
1. Total Framework of the Toyota Production System ............... 1 Primary Purpose ............................................................................................ 1 Kanban System ............................................................................................... 6 Production Smoothing .................................................................................... 8 Shortening Setup Time .................................................................................... 9 Process Layout for Shortened Lead Times .................................................... 10 Standardization of Operations ...................................................................... 11 Autonomation ............................................................................................... 12 Improvement Activities ................................................................................. 13 Summary ...................................................................................................... 13 PART
II
SUBSYSTEMS
2. Adaptable Kanban System Maintains Just-Io-Time Production ........................................................ 15 Pulling System for JIT Production ................................................................ 15 What Is a Kanban? ....................................................................................... 16 Kanban Rules ............................................................................................... 24 Other Types of Kanbans ............................................................................... 29
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vi
3. Supplier Kanban and the Sequence Schedule Used. by Suppliers ................................................................... 37 Monthly Information and Daily Information ................................................. 38 Later Replenishment System by Kanban ....................................................... 39 Sequenced Withdrawal System by the Sequence Schedule Table ................... 42 problems and Countermeasures in Applying the Kanban System to Subcontractors ............................................................................................. 46 G
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