Establishing based on many years of continuous improvements, with the objective of "making the vehicles ordered by customers in the quickest and most efficient way, in order to deliver the vehicles as quickly as possible.", so far, Toyota Production System (TPS) has became the truth to the great success of Toyota.
The Toyota Production System (TPS), which is steeped in the philosophy of "the complete elimination of all waste" imbues all aspects of production in pursuit of the most efficient methods. In other way, it is referred to as a "lean manufacturing system".
Based on two concepts including jidoka (which means that when a problem occurs, the equipment stops immediately, preventing defective products from being produced) and Just-in-Time (JIT), the TPS can efficiently and quickly produce vehicles of sound quality, one at a time, that fully satisfy customer requirements.
In June 1961, TMC decided to adopt the system of Total Quality Control (TQC) to modernize management operations. To realize TQC, all employees in Toyota were required to "regard the next processes (on the production line) as their customers and provide them with the required amount and quality of goods and services on a timely basis." Individual quality control circles studied ways of determining the cause of defects when they occurred and devised countermeasures to prevent reoccurrence. In addition, quality control teams were formed at all levels to promote company-wide participation. The first product to benefit from these improvements was the third generation Corona. Pressures to bring the second generation Corona to market as quickly as possible to meet market demand had led to early product defects, which, although later rectified, caused the car to be widely regarded as inferior in quality. After company-wide efforts to implement TQC, the new Corona was launched in September 1964 and proved its superior quality in the "100,000-km continuous high-speed driving test" conducted on highways in Japan. The high profile test — the likes of which had never been seen before — meant the Corona soon earned a reputation for exceptional high speed performance and durability. Thanks to continued efforts in quality improvement system, Toyota has become the famous brand over the world with Quality, Durability and Reliability in vehicles.
10 Basic rules to assure the Quality in process:
1. When getting a part in and out, confirm the KANBAN/part with the identification number and mark on the shelf (To prevent used wrong parts).
2. Get only required number of bolts/nuts out, and if dropped, the bolt/nut must be picked up immediately (to prevent any surplus part from mixing).
3. Do not use the part that is dropped or have any contact with anything (to prevent the use of any defective part).
4. Distinguish the defective part from others immediately by coloring in red, etc., and do not put it carelessly (to prevent any part from mixing).
5. Do not leave your post in the middle of the work in any case (to prevent operation omission/any mistake).
6. When following-up operation, clarify work allocation with the procedure sheet and then perform the follow-up (to prevent operation omission).
7. When the problem occur, immediately implement “Stop – Call – Wait” rule (to prevent repair omission)
8. When changing machine conditions, confirm the actual initial products of all concerned (to prevent initial product problem)
9. Even at the time of urgent change-over, be sure to notify in writing and put a new indication on the in-and-out mouth (to prevent wrong parts)
10. When changing workers, perform the work as mentioned in the instruction sheet and confirm its result (to prevent operation mistake)