Toyota Production System, 4th Edition

Toyota Production System, 4th Edition

by Yasuhiro Monden
Released October 2011
Publisher(s): Productivity Press
ISBN: 9781466504516

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Book description

A bestseller for almost three decades, Toyota Production System: An Integrated Approach to Just-In-Time supplies in-depth coverage of Toyota's production practices, including theoretical underpinnings and methods for implementation. Exploring the latest developments in the Toyota Production System (TPS) framework at Toyota, this new edition updates the classic with new material on e-kanban, mini-profit centers, computer-based information systems, and innovative solutions to common obstacles in TPS implementation.

Yasuhiro Monden, instrumental in introducing the JIT production system to the United States, explains the logic and methodologies of the TPS. Extending the humanized aspect of production introduced in the third edition, Toyota Production System: An Integrated Approach to Just-In-Time, Fourth Edition explains how to cultivate the culture and way of thinking needed to establish the TPS holistically across your organization. Exploring the link between kaizen methods and calculation methods in TPS, this edition includes new chapters on:

  • The goal of TPS
  • One-piece production in practice
  • Kaizen costing
  • Material handling in an assembly plant
  • Smoothing kanban collection
  • Determination of the number of kanban
  • New developments in e-kanban
  • Cultivating the spontaneous kaizen mind

Following in the footsteps of its bestselling predecessors, the fourth edition provides easy-to-follow guidance for implementing the TPS in your organization. It explains how Toyota has adapted and reacted to recent fluctuations in demand, quality problems, and recalls. It also includes an appendix that considers the recent tsunami in Japan and investigates how to reinforce the JIT system to ensure supply chain flow during sudden stoppages at individual locations within the chain.

Table of contents

  1. Front Cover
  2. Contents (1/4)
  3. Contents (2/4)
  4. Contents (3/4)
  5. Contents (4/4)
  6. Foreword to the First Edition
  7. Preface to the Fourth Edition (1/3)
  8. Preface to the Fourth Edition (2/3)
  9. Preface to the Fourth Edition (3/3)
  10. Preface to the Third Edition
  11. Preface to the Second Edition
  12. Acknowledgments
  13. About the Author
  14. Chapter 1: Total Framework of the Toyota Production System (1/5)
  15. Chapter 1: Total Framework of the Toyota Production System (2/5)
  16. Chapter 1: Total Framework of the Toyota Production System (3/5)
  17. Chapter 1: Total Framework of the Toyota Production System (4/5)
  18. Chapter 1: Total Framework of the Toyota Production System (5/5)
  19. Chapter 2: Implementation Steps for the Toyota Production System (1/2)
  20. Chapter 2: Implementation Steps for the Toyota Production System (2/2)
  21. Chapter 3: Adaptable Kanban System Maintains Just-In-Time Production (1/5)
  22. Chapter 3: Adaptable Kanban System Maintains Just-In-Time Production (2/5)
  23. Chapter 3: Adaptable Kanban System Maintains Just-In-Time Production (3/5)
  24. Chapter 3: Adaptable Kanban System Maintains Just-In-Time Production (4/5)
  25. Chapter 3: Adaptable Kanban System Maintains Just-In-Time Production (5/5)
  26. Chapter 4: Supplier Kanban and the Sequence Schedule Used by Suppliers (1/6)
  27. Chapter 4: Supplier Kanban and the Sequence Schedule Used by Suppliers (2/6)
  28. Chapter 4: Supplier Kanban and the Sequence Schedule Used by Suppliers (3/6)
  29. Chapter 4: Supplier Kanban and the Sequence Schedule Used by Suppliers (4/6)
  30. Chapter 4: Supplier Kanban and the Sequence Schedule Used by Suppliers (5/6)
  31. Chapter 4: Supplier Kanban and the Sequence Schedule Used by Suppliers (6/6)
  32. Chapter 5: Smoothed Production Helps Toyota Adapt to Demand Changes and Reduce Inventory (1/4)
  33. Chapter 5: Smoothed Production Helps Toyota Adapt to Demand Changes and Reduce Inventory (2/4)
  34. Chapter 5: Smoothed Production Helps Toyota Adapt to Demand Changes and Reduce Inventory (3/4)
  35. Chapter 5: Smoothed Production Helps Toyota Adapt to Demand Changes and Reduce Inventory (4/4)
  36. Chapter 6: The Information System for Supply Chain Management between Toyota, Its Dealers, and Parts Manufacturers (1/4)
  37. Chapter 6: The Information System for Supply Chain Management between Toyota, Its Dealers, and Parts Manufacturers (2/4)
  38. Chapter 6: The Information System for Supply Chain Management between Toyota, Its Dealers, and Parts Manufacturers (3/4)
  39. Chapter 6: The Information System for Supply Chain Management between Toyota, Its Dealers, and Parts Manufacturers (4/4)
  40. Chapter 7: How Toyota Shortened Production Lead Time (1/4)
  41. Chapter 7: How Toyota Shortened Production Lead Time (2/4)
  42. Chapter 7: How Toyota Shortened Production Lead Time (3/4)
  43. Chapter 7: How Toyota Shortened Production Lead Time (4/4)
  44. Chapter 8: Machine Layout, Multi-Functional Workers, and Job Rotation Help Realize Flexible Workshops (1/4)
  45. Chapter 8: Machine Layout, Multi-Functional Workers, and Job Rotation Help Realize Flexible Workshops (2/4)
  46. Chapter 8: Machine Layout, Multi-Functional Workers, and Job Rotation Help Realize Flexible Workshops (3/4)
  47. Chapter 8: Machine Layout, Multi-Functional Workers, and Job Rotation Help Realize Flexible Workshops (4/4)
  48. Chapter 9: One-Piece Production in Practice (1/2)
  49. Chapter 9: One-Piece Production in Practice (2/2)
  50. Chapter 10: Standard Operations Can Attain Balanced Production with Minimum Labor (1/4)
  51. Chapter 10: Standard Operations Can Attain Balanced Production with Minimum Labor (2/4)
  52. Chapter 10: Standard Operations Can Attain Balanced Production with Minimum Labor (3/4)
  53. Chapter 10: Standard Operations Can Attain Balanced Production with Minimum Labor (4/4)
  54. Chapter 11: Reduction of Setup Time—Concepts and Techniques (1/2)
  55. Chapter 11: Reduction of Setup Time—Concepts and Techniques (2/2)
  56. Chapter 12: 5S—Foundation for Improvements (1/5)
  57. Chapter 12: 5S—Foundation for Improvements (2/5)
  58. Chapter 12: 5S—Foundation for Improvements (3/5)
  59. Chapter 12: 5S—Foundation for Improvements (4/5)
  60. Chapter 12: 5S—Foundation for Improvements (5/5)
  61. Chapter 13: Autonomous Defect Control Ensures Product Quality (1/4)
  62. Chapter 13: Autonomous Defect Control Ensures Product Quality (2/4)
  63. Chapter 13: Autonomous Defect Control Ensures Product Quality (3/4)
  64. Chapter 13: Autonomous Defect Control Ensures Product Quality (4/4)
  65. Chapter 14: Cross-Functional Management to Promote Company-Wide Quality Assurance and Cost Management (1/4)
  66. Chapter 14: Cross-Functional Management to Promote Company-Wide Quality Assurance and Cost Management (2/4)
  67. Chapter 14: Cross-Functional Management to Promote Company-Wide Quality Assurance and Cost Management (3/4)
  68. Chapter 14: Cross-Functional Management to Promote Company-Wide Quality Assurance and Cost Management (4/4)
  69. Chapter 15: Kaizen Costing (1/3)
  70. Chapter 15: Kaizen Costing (2/3)
  71. Chapter 15: Kaizen Costing (3/3)
  72. Chapter 16: Material Handling in an Assembly Plant (1/2)
  73. Chapter 16: Material Handling in an Assembly Plant (2/2)
  74. Chapter 17: Further Practical Study of the Kanban System (1/3)
  75. Chapter 17: Further Practical Study of the Kanban System (2/3)
  76. Chapter 17: Further Practical Study of the Kanban System (3/3)
  77. Chapter 18: Smoothing Kanban Collection (1/2)
  78. Chapter 18: Smoothing Kanban Collection (2/2)
  79. Chapter 19: Applying the Toyota Production System Overseas (1/4)
  80. Chapter 19: Applying the Toyota Production System Overseas (2/4)
  81. Chapter 19: Applying the Toyota Production System Overseas (3/4)
  82. Chapter 19: Applying the Toyota Production System Overseas (4/4)
  83. Chapter 20: Sequencing Method for the Mixed-Model Assembly Line to Realize Smoothed Production (1/3)
  84. Chapter 20: Sequencing Method for the Mixed-Model Assembly Line to Realize Smoothed Production (2/3)
  85. Chapter 20: Sequencing Method for the Mixed-Model Assembly Line to Realize Smoothed Production (3/3)
  86. Chapter 21: New Sequence Scheduling Method for Smoothing (1/4)
  87. Chapter 21: New Sequence Scheduling Method for Smoothing (2/4)
  88. Chapter 21: New Sequence Scheduling Method for Smoothing (3/4)
  89. Chapter 21: New Sequence Scheduling Method for Smoothing (4/4)
  90. Chapter 22: Computation of the Number of Kanban (1/5)
  91. Chapter 22: Computation of the Number of Kanban (2/5)
  92. Chapter 22: Computation of the Number of Kanban (3/5)
  93. Chapter 22: Computation of the Number of Kanban (4/5)
  94. Chapter 22: Computation of the Number of Kanban (5/5)
  95. Chapter 23: New Developments in e-Kanban (1/2)
  96. Chapter 23: New Developments in e-Kanban (2/2)
  97. Chapter 24: Kanban Supporting Information Systems (1/3)
  98. Chapter 24: Kanban Supporting Information Systems (2/3)
  99. Chapter 24: Kanban Supporting Information Systems (3/3)
  100. Chapter 25: Cultivating the Spontaneous Kaizen Mind (1/2)
  101. Chapter 25: Cultivating the Spontaneous Kaizen Mind (2/2)
  102. Chapter 26: Improvement Activities Help Reduce the Workforce and Increase Worker Morale (1/6)
  103. Chapter 26: Improvement Activities Help Reduce the Workforce and Increase Worker Morale (2/6)
  104. Chapter 26: Improvement Activities Help Reduce the Workforce and Increase Worker Morale (3/6)
  105. Chapter 26: Improvement Activities Help Reduce the Workforce and Increase Worker Morale (4/6)
  106. Chapter 26: Improvement Activities Help Reduce the Workforce and Increase Worker Morale (5/6)
  107. Chapter 26: Improvement Activities Help Reduce the Workforce and Increase Worker Morale (6/6)
  108. Chapter 27: Respect-for-Humanity Subsystem in the JIT Production System (1/4)
  109. Chapter 27: Respect-for-Humanity Subsystem in the JIT Production System (2/4)
  110. Chapter 27: Respect-for-Humanity Subsystem in the JIT Production System (3/4)
  111. Chapter 27: Respect-for-Humanity Subsystem in the JIT Production System (4/4)
  112. Chapter 28: Motivational and Productivity Effects of Autonomous Split-Lines in the Assembly Plant (1/4)
  113. Chapter 28: Motivational and Productivity Effects of Autonomous Split-Lines in the Assembly Plant (2/4)
  114. Chapter 28: Motivational and Productivity Effects of Autonomous Split-Lines in the Assembly Plant (3/4)
  115. Chapter 28: Motivational and Productivity Effects of Autonomous Split-Lines in the Assembly Plant (4/4)
  116. Chapter 29: Mini Profit Centers and the JIT System (1/4)
  117. Chapter 29: Mini Profit Centers and the JIT System (2/4)
  118. Chapter 29: Mini Profit Centers and the JIT System (3/4)
  119. Chapter 29: Mini Profit Centers and the JIT System (4/4)
  120. Appendix: Reinforcing the JIT System after the Disasters of 3/11/2011, Japan (1/2)
  121. Appendix: Reinforcing the JIT System after the Disasters of 3/11/2011, Japan (2/2)
  122. Bibliography and References (1/3)
  123. Bibliography and References (2/3)
  124. Bibliography and References (3/3)
  125. Back Cover

Product information

  • Title: Toyota Production System, 4th Edition
  • Author(s): Yasuhiro Monden
  • Release date: October 2011
  • Publisher(s): Productivity Press
  • ISBN: 9781466504516