# Toyota Production System

**URL:** https://kaizumi.com/dictionary/toyota-production-system

**Description:** The Toyota Production System (TPS) is Toyota's integrated manufacturing approach combining just-in-time, jidoka, and respect for people.

**Category:** lean-principles

**Tags:** foundational

## 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. For a visual tour of how the pieces work together on a final assembly line — takt, standardized work, andon, kanban, supermarkets, and milk runs — see the [interactive Toyota assembly guide](/guides/toyota-assembly).

## Examples

### Manufacturing

> 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.

### Healthcare

> Virginia Mason Medical Center adopted TPS principles as the Virginia Mason Production System. They implemented standard work for clinical procedures, created flow in patient movement, used visual management for status visibility, and engaged frontline staff in daily improvement. Quality improved while costs decreased.

### Administrative

> Progressive Insurance applied TPS principles to claims processing. They created flow from claim to payment, implemented visual management for claim status, used standard work for consistent processing, and engaged adjusters in continuous improvement. Claims processing time dropped from weeks to hours.

## 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.

## See Also

- [Respect for People](/dictionary/respect-for-people) - The people pillar of the philosophy underlying TPS

Source: https://kaizumi.com/dictionary/toyota-production-system
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