Toyota Production System — Canon
The Toyota Production System (TPS) is an integrated socio-technical system for producing value with reliability by eliminating waste, making problems visible, and continuously improving both process and people.
Core Principles
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Genchi Genbutsu (現地現物)
Go and see for yourself. True understanding comes from direct observation of the real situation, not reports or abstractions. -
Genba (現場)
The actual place where value is created. All meaningful improvement begins at the genba, where work is visible and accountable. -
Kaizen (改善)
Continuous improvement through small, incremental changes. Perfection is pursued asymptotically, never claimed. -
Just-In-Time (JIT)
Produce only what is needed, when it is needed, and in the amount needed. A pull-based system aligned to customer demand. -
Jidoka (自働化)
Automation with human intelligence. Systems are designed to detect abnormalities, stop automatically, and surface problems immediately. -
Andon (行灯)
A visible signal indicating that action is required. Any worker may stop the line to address a problem at its source. -
Heijunka (平準化)
Production leveling. Smooths workload and demand variation to reduce waste and instability. -
Kanban (看板)
A signaling system that coordinates flow between processes and enables Just-In-Time production. -
Poka-Yoke (ポカヨケ)
Mistake-proofing. Design processes and constraints that prevent errors or make them immediately obvious. -
Hansei (反省)
Structured self-reflection. Even success requires reflection to identify gaps, assumptions, and opportunities for improvement. -
Nemawashi (根回し)
Laying the groundwork. Informal consensus-building before formal decisions are made, enabling smooth implementation. -
Muda / Muri / Mura (無駄 / 無理 / 斑)
The three sources of waste: non–value-adding activity, overburden, and unevenness. Elimination of these is central to system reliability. -
Konnyaku Stone
A metaphor of finishing. Small, deliberate abrasion removes imperfections that would otherwise propagate downstream.
TPS is not optimized for speed or efficiency in isolation. It is optimized for reliability, quality, and long-term learning.