Toyota Production System
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The Toyota Production System (TPS) is Toyota's integrated manufacturing approach combining just-in-time, jidoka, and respect for people.
Definition
The Toyota Production System (TPS) is Toyota's integrated approach to manufacturing, developed over decades starting in the 1940s primarily by Taiichi Ohno and Eiji Toyoda. TPS is often visualized as a house: the foundation is stability and standardization; the two pillars are just-in-time (producing only what is needed, when needed) and jidoka (automation with human intelligence); the roof represents the goals of highest quality, lowest cost, and shortest lead time. TPS became the basis for lean manufacturing and lean thinking worldwide.
Examples
Toyota's Georgetown, Kentucky plant demonstrates TPS in action. Pull systems trigger production based on dealer orders. Andon cords allow any worker to stop the line for quality problems. Standardized work defines the best-known method for each job. Team members rotate through roles and participate in kaizen. The result: world-class quality with remarkably high productivity.
Key Points
- TPS is an integrated system, not a collection of tools—elements work together
- The foundation (stability and standardization) must be established before the pillars
- Both pillars (JIT and jidoka) are essential; one without the other creates problems
- TPS evolved over decades through countless experiments and adjustments
Common Misconceptions
TPS can be copied quickly. Toyota itself says their advantage isn't the system but the culture and capability to improve it continuously. Organizations can adopt TPS principles but developing Toyota-like capability takes years of practice and learning.
TPS is only about manufacturing efficiency. TPS includes deep commitment to people development, problem-solving capability, and long-term thinking. The visible tools rest on an invisible foundation of culture and management philosophy.