Toyota Production System(TPS) is a business system for organizing and managing product development, operations, suppliers, and customer relations. Organizations use lean principles, practices, and tools to create precise customer value—goods and services with higher quality and fewer defects—with less human effort, less space, less capital, and less time than the traditional approaches.
One of the primary focuses of TPS is to eliminate waste; that is, anything that does not add value to the final product gets eliminated. A second major focus is to empower people at lowest level, and make operational decisions at the lowest level possible.
TPS is about looking at the whole picture of all the processes that are required to deliver a product or service. It is about evaluating each step and ensuring that the step is Valuable, Capable, Available, Flexible and Adequate.
TPS has been successfully implemented and practiced in manufacturing industries like Textiles and Apparel, Automotive, Industrial Products, Furniture, Printing and Packaging, Consumer Products and Healthcare industries, Military and Service sector. Lean applies to non manufacturing settings just as strongly.
This course will aim at explaining the concepts of TPS, learn about various tools used for implementing and the technicalities involved in order to reduce or eliminate waste, reduce lead time, cost and thereby increase productivity and profitability of the organization.
Workshop topics to be covered:
Definition of Toyota production System
Objective of Toyota Production System
Framework Of Toyota Production System
Explaining 25 TPS Tools
Effect of TPS Tools in Garment Manufacturing
Waste and Allowance:
What is Waste
Details of Waste(MUDA; MURI; MURA)
Wastes in RMG Manufacturing(Effects and solution)
What is allowance?
Different kinds of allowance
How to find allowance in Garment manufacturing
How to analyze the effect of Allowance
How to measure performance by Allowance calculator software
How eliminate allowance to reduce time and improve productivity
Practical exercise and sudden tests and evaluations
What is 6S
Criteria’s of 6S
Impact of 6S in Garment industry
How to analyze, evaluate and measure performance by 6S
What is Kanban
How to use Kanban in Store, Cutting, Sewing and Finishing
Effect of Kanban system in reduce time and reduce waste
What is Visual Management?
Examples of Visual Managements in Every area of Garment manufacturing
Effects of Visual Management to reduce waste, improve efficiency improve quality
Linear flow in Production:
What is linear flow?
How linear flow effects on reducing time, eliminate waste, improve quality, improve productivity
Examples of linear flow system in Cutting, Sewing, Finishing, Packing
What is work standardization?
How work standardization effects on higher quality, higher productivity, Lower cost and time
Examples of Work standardization All section of garment manufacturing
Value Stream Mapping(VSM):
VSM in Cutting
VSM in Sewing
Effects of VSM in Higher quality, higher productivity, Lower cost and time
Measuring Peoples by KPI:
What is KPI
Why KPI is important to perform the team better
How to set KPI for different section different peoples
How KPI can drive to higher efficiency, higher work satisfaction and self motivation