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Toyota Production System

We apply lean manufacturing to our production and work according to a pull system, which means we only produce what you order. In this way we can produce everything just in time, generating a smooth workflow. But of course we continuously do quality checks and improve our processes along the way.

How TPS can benefit your operation

  • High quality    
  • Value for money  
  • On-time delivery  
  • Environmentally friendly  
  • Health & safety

Working with TPS allows us to produce high-quality, cost-effective products, that are delivered to you on time. Our production respects the environment, which includes recycling our products at the end of their lifetime. We create a safe workplace, both for our employees and our customers.

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TPS fundamentals

How TPS guarantees quality trucks

Just in time

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 - The term Heijunka describes the foundation of the TPS approach to just-in-time processes – ones in which inventory costs are minimised by having the parts required arrive at their point of use 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. The key is that the work-cycle should be synchronised with demand to avoid under or overproduction.

  • Kanban card – In order to have flexibility and efficient, smooth workflows, it is necessary to have the right things at the right place at the right time. The Kanban card is the device that TPS uses to call up components as they are required.

Jidoka: making problems visible 

Jidoka builds quality checks into each step of the production process. By ensuring that all processes are visible, jidoka helps ensure that abnormalities are made visible and addressed immediately.

  • Genchi Genbutsu –  Improvements are often made as a result of discovering problems. Therefore, problems need to be properly understood through genchi genbutsu, which means ‘going to the source’ of the problem and assessing it yourself.

  • Andon board – The andon board is a electronic sign displaying the status of production lines. It notifies management immediately if a worker has identified a fault, precisely identifying its location. The production line will not be restarted until the reason for the fault has been resolved.

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

Woman working in the factory

What TPS means for our team members

  • A strong culture of safety and quality
  • Well-defined responsibilities
  • The opportunity to work at different stations and develop skill set

Thanks to our long experience in TPS, we can offer you the quality solutions your operations need. We are also confident to give our employees well-defined responsibilities, which encourages them to continuously improve and develop.

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