Articles

Image: Genchi Genbutsu

Genchi Genbutsu: A Way to First-Hand Process Observation

Imagine you’re a business leader faced with a persistent operational issue that’s hurting productivity and customer satisfaction. You’ve pored over reports, analyzed data, and held countless meetings, yet the root cause remains elusive. This disconnect between perception and reality is a common challenge that the Japanese philosophy of “genchi genbutsu” can help overcome. Genchi genbutsu, […]

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What is Mura, Toyota Production System? All You Need to Know

Mura, a Japanese term, denotes unevenness within manufacturing or workflow. It comprises one type of waste alongside muda and muri per the Toyota Production System, lean’s foundation. Forms involve demand fluctuations, unbalanced workloads, and variable cycle times. Mura enables muri, overburdening employees, tools, and processes. This decreases productivity and quality while wasting resources. Thus eliminating […]

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Image: Toyota 3m model (Muda, Muri, Mura)

The Toyota 3M Model: Unlocking Lean Manufacturing Mastery

Companies always look for ways to smooth out their work flows, remove wasted effort and maximize productivity. At the core of this objective lies the famous Toyota 3M Model, a time-tested framework that transformed manufacturing for many industries. The Toyota 3M Model, based on the groundbreaking ideas behind Toyota’s Production System, zeroes in on pinpointing […]

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Lean Thinking for Continuous Improvement. Toyota Production System

Modern organizations require modern technology but also a change on the operational side. They require methodologies that transform them from within and drive efficiency, growth, reduce waste, and establish a competitive edge. With lean thinking, the name of the game is always striving for perfection through constant improvement and respecting the people doing the work. […]

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Jidoka – Toyota Production System. A Complete Guide (2024)

Jidoka, often referred to as “autonomation” or “intelligent automation,” is a fundamental principle of the renowned Toyota Production System (TPS) and a cornerstone of lean manufacturing. This powerful quality control concept empowers workers to detect defects, stop production, and address quality issues immediately, rather than allowing problems to propagate through the manufacturing process. Want to […]

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What Will Kaizen Be like in 100 Years?

As with any great system of operations or technique of processes, it advances and evolves on its own. Kaizen is one of those simple miracles that actually implements its own technique automatically. So what will be the state of Kaizen in 100 years? As we all know, Kaizen is a Japanese word that means “change […]

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Image: Toyota Production System (TPS) - Making of a Post war Automotive Star

The Toyota Production System (TPS) – The Making of a Post war Automotive Star

It is said that the rise and rise of Toyota can be attributed to the philosophy, now termed the TPS (Toyota production system.) Developed in part by Toyota’s vice president Taiichi Ohno and its founder Sakichi Toyoda during the post war decades, Toyota’s phenomenal success has been attributed to its implementation. On the basis of […]

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Benefits of Toyota Production System (TPS)

Toyota production system (TPS) is like a supercharged Lean Six Sigma program. All the proven and intelligent methodologies of conventional TPS Six Sigma have been charged with immensely motivated team associates. TPS is the outcome of such powerful Lean Six Sigma team associates sigma, which leads to a high-performance culture and lets employees to know […]

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Bringing Toyota Close to Home

Your company need not be in the automotive industry to benefit from the principles of the Toyota Production System. Whether you’re running a critical care unit, overseeing cross-country trucking operations or opening an art school, you can learn valuable lessons from the Toyota Production System. We’ll apply TPS in certain situations to bring some principles into […]

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