Toyota Production System (TPS) Goals

The right process will produce the right results
1. Create continuous process flow to bring problems to the surface
2. Use the "pull" system to avoid overproduction
3. Level out the workload (heijunka). (Work like the tortoise, not the hare.)
4. Build a culture of stopping to fix problems, to get quality right from the first
5. Standardized tasks are the foundation for continuous improvement and employee empowerment
6. Use visual control so no problems are hidden
7. Use only reliable, thoroughly tested technology that serves your people and processes.


Add value to the organization by developing your people and partners
1. Grow leaders who thoroughly understand the work, live the philosophy, and teach it to others.
2. Develop exceptional people and teams who follow your company's philosophy.
3. Respect your extended network of partners and suppliers by challenging them and helping them improve.


Continuously solving root problems drives organizational learning
1. Go and see for yourself to thoroughly understand the situation (Genchi Genbutsu);
2. Make decisions slowly by consensus, thoroughly considering all options (Nemawashi); implement decisions rapidly;
3. Become a learning organization through relentless reflection (Hansei) and continuous improvement (Kaizen).

Toyota Production System

The Toyota Production System (TPS) is an integrated socio-technical system, developed by Toyota, that comprises its management philosophy and practices. The TPS organizes manufacturing and logistics for the automobile manufacturer, including interaction with suppliers and customers. The system is a major precursor of the more generic "Lean manufacturing." Taiichi Ohno, Shigeo Shingo and Eiji Toyoda developed the system between 1948 and 1975.

Originally called "Just In Time Production," it builds on the approach created by the founder of Toyota, Sakichi Toyoda, his son Kiichiro Toyoda, and the engineer Taiichi Ohno. The founders of Toyota drew heavily on the work of W. Edwards Deming and the writings of Henry Ford. When these men came to the United States to observe the assembly line and mass production that had made Ford rich, they were unimpressed. While shopping in a supermarket they observed the simple idea of an automatic drink resupplier; when the customer wants a drink, he takes one, and another replaces it. The principles underlying the TPS are embodied in The Toyota Way.

Source: Wikipedia

5 Principle of ACE Cell Line Design

ACE Cell Line Design for manufacturing production system is based on five principles:

1. Cell work table maximum height is 160cm (Visual Management)
2. Material arrangement height between navel to chest (Moving Loss) is 120 degree from front side
3. Movable distance during Cell operation (Moving Loss) is one step
4. Equipment and tools are easy to convert or changeable (Direct Improvement)
5. Line construction type is one person completion to reach Line of Balance or LoB 100% (Composition Loss)

ACE Cell Line Manufacturing Production System

ACE or Advanced Creative Environment is a name of DMC Biz Cell Line that contains the meaning of 'Creativity' and 'Development'.

ACE Cell Line is developed and applied considering to culture, customs, environment and so on of each nations of subsidiaries.

Cell Line Manufacturing Production System

Cell Production System is production system that a single human worker assembles each product from start to finish almost manually. Cell Production System is more flexible than conveyor system.

Kind of Cell Production System:

1. Single Worker Completion Cell or One Person Completion.
2. Circulation Completion Cell or Rotation Syste.
3. Separation Completion Cell.
4. Block Synchronized Cell.

Green Manufacturing Office

Green Manufacturing Office is mind concept to eliminate waste in our circumstance. The goal is to enhance productivity, quality and working efficiencies for each personal and also for all factory. Types of waste are:

1. Error and problem on documents
2. Documents transportation
3. Doing unnecessary work
4. Waiting next process too long
5. Complicated approval process
6. Unnecessary activity
7. Backlog in work queues
8. Underutilized employees

8 Habits to be Great People

Here is tips to be a great people in your community:

1. Be Proactive
2. Begin with the end in mind
3. Put first thing first
4. Think to be a winner
5. Try to understand, not to be understood
6. Synergize
7. Sharpen your mind
8. Find your view and inspire others to find theirs

PRO 3M (My Machine, My Area, My Job)

PRO 3M is a campaign activity of My-Machine, My-Area and My-Job which is similar to Japan's TPM, but developed to be professional. PRO 3M comprised initially 5 steps:
Step 0: Making basic environment base on 5S principle.
Step 1: Satisfying Machine standards.
Step 2: Making loss-less machine.
Step 3: Making action standard.
Step 4: Making preserve ability to operator.

Total Productivity Maintenance (TPM)

Total Productivity Maintenance (TPM) is a maintenance program which involves a newly defined concept for maintaining plants and equipment. The goal of TPM program is to markedly increase production while, at the same time, increasing employee morale and job satisfaction by reducing loss in work process and equipment. The basic TPM activities is 5S.