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Toyota Production Documentary – Toyota Manufacturing Production and Assembly at Toyota Factory

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Toyota Production Documentary – Toyota Manufacturing Production and Assembly at Toyota Factory

Toyota follows a lean manufacturing process, known as the Toyota Production System (TPS). TPS focuses on reducing waste and maximizing efficiency in the production process. This is achieved through the use of Just-In-Time (JIT) inventory management, where parts and materials are delivered to the assembly line as they are needed, rather than being stockpiled in advance. TPS also emphasizes continuous improvement, with workers actively identifying and solving problems on the assembly line. In addition, Toyota uses a modular assembly process, where subassemblies are built separately and then brought together to form the final product. This allows for greater flexibility in the production process and makes it easier to introduce new models or make changes to existing ones.

This video shows Toyota manufacturing production and assembly at the Toyota factory. The Toyota Production System (TPS) is what has given Toyota a world class supply chain and quality program.

Lean and Toyota Manufacturing Blogs

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Lean Quotes

  • “Why not make the work easier and more interesting so that people do not have to sweat?  The Toyota style is not to create results by working hard. It is a system that says there is no limit to people’s creativity.  People don’t go to Toyota to ‘work’ they go there to ‘think’”   ~ Taiichi Ohno
  • “An hour saved at the non-bottleneck is a mirage.”   ~ Eliyahu M. Goldratt, The Goal
  • “Where there is no Standard there can be no Kaizen.”  ~ Taiichi Ohno
  • “If you can make time to fix problems you can make time to plan so problems don’t occur.” ~ Dave Waters
  • “For much of Toyota’s history, we have ensured the quality and reliability of our vehicles by placing a device called an andon cord on every production line – and empowering any team member to halt production if there’s an assembly problem. Only when the problem is resolved does the line begin to move again.”  ~ Akio Toyoda, CEO Toyota Motor Company
  • “I say an hour lost at a bottleneck is an hour out of the entire system. I say an hour saved at a non-bottleneck is worthless. Bottlenecks govern both throughput and inventory.”   ~ Eliyahu M. Goldratt, The Goal
  • “Improvement usually means doing something that we have never done before.” ~ Shigeo Shingo
  • “When you are out observing on the gemba, do something to help them. If you do, people will come to expect that you can help them and will look forward to seeing you again on the gemba.”  ~ Taiichi Ohno
  • “Perfection is achieved, not when there is nothing more to add, but when there is nothing left to take away.” ~Antoine de Saint Exupery
  • “It is impossible to improve any process until it is standardized. If the process is shifting from here to there, then any improvement will just be one more variation that is occasionally used and mostly ignored. One must standardize, and thus stabilize the process, before continuous improvement can be made.”  ~ Masaaki Imai
  • “Quality is never an accident; it is always the result of high intention, sincere effort, intelligent direction and skillful execution; it represents the wise choice of many alternatives.” ~William A Foster
  • “Many people think that Lean is about cutting heads, reducing the work force or cutting inventory. Lean is really a growth strategy. It is about gaining market share and being prepared to enter in or create new markets.”  ~ Ernie Smith
  • “All we are doing is looking at the time line, from the moment the customer gives us an order to the point when we collect the cash. And we are reducing the time line by reducing the non-value adding wastes.”  ~ Taiichi Ohno, father of Toyota Production System (TPS)
  • “Out of clutter, find simplicity. From discord, find harmony. In the middle of difficulty lies opportunity.” ~ Albert Einstein
  • “A relentless barrage of “why’s” is the best way to prepare your mind to pierce the clouded veil of thinking caused by the status quo.  Use it often.”  ~ Shigeo Shingo
  • “Don’t look with your eyes, look with your feet. Don’t think with you head, think with your hands.”  ~ Taiichi Ohno
  • “The key to the Toyota Way and what makes Toyota stand out is not any of the individual elements…But what is important is having all the elements together as a system. It must be practiced every day in a very consistent manner, not in spurts.” ~ Taiichi Ohno
Toyota Manufacturing