The Illustrated Toyota Production System, Vol. 2

By Jon Miller | Post Date: June 16, 2010 1:13 AM | Comments: 0

We are pleased to bring to you The Illustrated Toyota Production System, Volume 2. This is a book that sheds light on lean manufacturing practices and in particular the Industrial Engineering underpinnings of TPS. Building on the overview of philosophy, principles and systems provided in Volume 1, the second half gives 60 practical lessons on kaizen and industrial engineering approaches and their use.

To celebrate the publishing of this book in English, we are offering a 2-for-1 sale through the month of June. Click on the banner above or visit www.gemba-shop.com and enter the coupon code TPSGEMBA upon checkout.

Each book is about 130 pages, half of which are illustrations of various principles and tools.

lesson 38 tps 2.png

Volume 2 contains 60 lessons made up of one page of text and one supporting illustration, such as the one below from "Lesson 38: Education and Training Help People See Waste".

lesson 38 tps 2 illustration.png

The book is organized into four sections as shown below:

Section 1. What Is Kaizen?

1. Kaizen Is Built on Respect for People
2. A Key to Toyota's Outstanding Success
3. Sharing Information through Visualization
4. Creating a Common Understanding of Work through Visual Management
5. Examples of Visual Management
6. Knowledge Is Not Sufficient--Creativity Is Needed
7. We Know Defects Are Waste--Why Can't We Kaizen Them Away?
8. Understand Time-Tested and Proven Problem Solving Techniques
9. Kaizen Must Be Workplace-Centered
10. Understand the True Nature of Defects
11. How to Find the Root Causes of Defects in the Workplace
12. Getting Rid of the Waste of Inspection
13. Causes of Careless Mistakes & the Pokayoke Concept
14. Three Approaches to Pokayoke
15. How to Cope with Unplanned Minor Stops of Equipment
16. How Can We Learn to See Waste?
17. What to Do When You Cannot Find Topics for Kaizen

Section 2. Industrial Engineering (IE) Methods Are the
Foundation of Kaizen at Toyota

18. What Are IE Methods?
19. The First Step Toward Productivity Improvement Is to Study the Work
20. What Is Process Analysis?
21. What Is Motion Analysis?
22. Reducing the Number of Motions Using Motion Economy Principles
23. Making Work Easier Using Motion Economy Principles
24. What Are Standard Times?
25. Using the Work Sampling Method to Understand the Process
26. How to Use Work Sampling
27. How to Use Random Timetables
28. Case Example of Analysis in a Workplace with Poor Visibility
(Distribution Warehouse)
29. How to Find Waste within a Flow Process
30. How to Do Line Balancing Analysis
31. How to Kaizen Line Balancing

Section 3. Achieving Manpower Savings by Analyzing
Each Process

32. How to Recognize Waste of Transportation
33. Aiming for Zero Transportation
34. Various Types of Transportation Methods in Use at Toyota
35. Don't Overlook the Waste within Processes
36. Clarify the Roles of People and Machines
37. Enabling Multi-machine Operation at Injection Molding Plants
38. Education and Training Help People See Waste
39. Proven Techniques Help Expose Problems
40. We Reduced Our Machine Problems to Zero, So Why Can't We Implement
Multiple-Machine Handling?
41. Develop Powers of Observation So Busywork Does Not Fool You
42. Not Only Did We Succeed with Multi-machine Handling and Manpower Saving,
but the Work Became Easier
43. Points to Focus on When Performing a Large Number of Operations
44. Making Work Easier By Applying Motion Economy Principles
45. Be Mindful of Small Details Such as Lighting

Section 4. Kaizen of Flow Lines Using Time Analysis

46. All Waste Is Connected to the Waste of Waiting
47. The Concepts of Takt Time and Line Balancing
48. Operation Improvement through Continuous Time Analysis
49. Case Example of Time Analysis
50. How to Document the Time Study
51. Kaizen in a Flow Line with Six Operators
52. Finding Hints for Kaizen Within Parts Drawings
53. Begin Kaizen by Using Proven Techniques
54. The Wonder of Video Analysis: Products Are Made Faster than the
Time of the Bottleneck Process
55. Eliminating Busywork and Non-Value Added Work
56. Doubling Productivity through Line Balancing by Applying Motion
Economy Principles
57. Don't Overlook the Seconds of Kaizen Opportunity
58. Find Waste in Motion Elements by Using Motion Economy Principles
59. Waste of Motion and Waste of Waiting
60. Toyota-style IE Is a Total Company Approach Linked Directly to Profit

I think this book will be helpful to a lot of people. It's also a good opportunity to pick up both volumes 1 and 2 for the price of one, through June 30th, 2010.

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