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What is the Toyota Production System?

We’re very proud that all of our trucks are manufactured using the world renowned Toyota Production System (TPS) which guarantees the highest levels of quality, durability and reliability in our equipment.

We’re very proud that all of our trucks are manufactured using the world renowned Toyota Production System (TPS) which guarantees the highest levels of quality, durability and reliability in our equipment.

We apply lean manufacturing processes in all of our production and work to a pull system, meaning that all equipment is produced to order. This ensures that we can deliver your products just in time which results in a smooth workflow.

TPS is based on key principles which we uphold to ensure that your products are the highest quality whilst remaining cost-effective.


TPS fulfills customer demand efficiently and promptly by linking all production activity to real marketplace demand. Just-in-time production relies on finely tuned processes in the assembly sequence using only the quantities of items required, only when they are needed.

  • Heijunka (levelling the flow) – Heijunka describes the approach in which costs are minimised by having the parts required arrive only as they are needed.

  • Muda (elimination of waste) – Waste – defined as anything that does not add value.

  • Takt time – The term given to a work-cycle that fulfills each customer’s demand.

  • Kanban card – This is the device that TPS uses to call up components as they are required.

Toyota Production System house

Jidoka: making problems visible 

By ensuring that all processes are visible, Jidoka helps ensure that abnormalities are made visible and addressed immediately.

  • Standardisation – Developing standardised tasks not only ensures consistently high levels of quality, but also maintains production pace and provides a benchmark for implementing continuous improvement.

  • Genchi Genbutsu – Improvements are often made as a result of discovering problems. Genchi Genbutsu means ‘going to the source’ of the problem and assessing it yourself to ensure it is properly understood.

  • Andon board – The Andon board is an electronic sign that notifies management immediately if a worker has identified a fault. The production line will not be restarted until the fault has been resolved.

  • Poka Yoke – A process that is put in place to check and ensure errors are not passed on.

Kaizen: continuous improvement

At Toyota change is a way of life, thanks to the company’s fundamental philosophy of continuous improvement known as Kaizen. Kaizen means that all team members throughout the organisation are continuously looking for ways to improve operations.

  • The ‘Thinking People System’ – In TPS, team members are invited to think about the process and make timely decisions in order to keep it running smoothly, rather than merely operating like machines.

  • 5 Whys? – Every planned improvement needs to be tested by questioning ‘why?’ at five levels to ensure that the logic and value of the improvement is clear.

  • ‘5S’ – Toyota takes care to nurture a sense of pride and efficiency in the workplace. This is supported by ‘5S’: Sifting, Sorting, Sweeping, Spic-and-span, Sustain. This ensures that every team member is involved in keeping processes as efficient as possible.


To find out more about the Toyota Production System, call 0370 850 1409 or click here 

To request a copy of our TPS Whitepaper click here.


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