Toyota Production System

Manufacturing is one of the important activity for wealth generation. Countries like China, Thailand, Vietnam etc are creating an enabling environment for developing these nations as major industrial ones. Therefore, there is an increasing interest in manufacturing activities. Toyota car company at Japan is a very interesting case study to learn many things to make manufacturing competitive. Toyota consistently raises the bar for manufacturing, product development, and process excellence. The result is an amazing business success story: steadily taking market share from price cutting competitors, earning far more profit than any other automaker, and winning the praise of business leaders worldwide.
The proposed course will discuss various aspects of Toyota’s approach and will also focus to achieve sustainability through excellence in operations
INTENDED AUDIENCE: (1) Industry people who wants to use “operations” for competitive advantage. (2) Students doing research in operations management. (3) Students doing Masters and Bachelors degrees in area of operations management, industrial engineering etc. (4) Professionals who are interested in knowing the best practices in operations.
PREREQUISITES: Production and Operations Management
INDUSTRY SUPPORT: This course will be highly useful for manufacturing organizations. Particularly companies such as Hero,
Maruti, BHEL, Rockman, Bajaj, Tata etc. will find this course valuable

COURSE LAYOUT

Week 1: (1) Manufacturing Excellence (2) Global Environment (3) Production System (4) Operations Strategy (5) The Heart of the TPS: Eliminating Waste
Week 2: (1) Principles of Toyota Way (2) Culture Behind Toyota Way (3) Toyota Way in Action (4) Long Term Philosophy (5) Create Continuous Flow
Week 3: (1) Pull System (2) Leveling Workload (3) Get Quality Right the first time (4) Standardization of Task (5) Use of Visual Control Week 4: (1) Use of Reliable Technology (2) Role of Leaders in Manufacturing Philosophy (3) Developing Exceptional Teams (4) Challenge & Respect Extended Networks (5) See yourself to understand the situation Week 5: (1) Developing decisions with Consensus (2) Becoming Learning Organization (3) Becoming a Learning Organization: Continuous Improvement (4) Using Toyota Way for other Organization(Service & Technical) (5) Lean Manufacturing
Week 6: (1) Lean Vs Agile Manufacturing (2) Sustainable Manufacturing-I (3) Sustainable Manufacturing-II (4) Flexible Manufacturing System (5) Benchmarking Week 7: (1) Cultural Issues in Lean (2) Overview of Lean implementation (3) Significance of Lead time (4) Techniques to reduce LT (5) Value Stream Mapping
Week 8: (1) KANBAN Approach (2) KANBAN Calculation-I (3) KANBAN Calculation-II (4) Theory of Constraints (5) Different Business Excellence Models