Sistema de Producción Toyota (TPS) Lean Manufacturing, subtitulado al español
Summary
TLDREl sistema de producción Toyota, conocido por su eficiencia y calidad, se originó con Sakichi Toyoda y su invento de una tela de arpillera automática. Este sistema se caracteriza por la inteligente automatización (jidoka) y la fabricación just-in-time, lo que elimina el desperdicio y mejora la productividad. A través de la implementación de tarjetas Kanban y la colaboración con trabajadores, Toyota logra un flujo sin interrupciones en su línea de montaje, asegurando una producción de alta calidad y en tiempo oportuno. Hoy en día, el sistema de producción Toyota es un estándar en la industria manufacturera y ha ganado seguidores a nivel mundial.
Takeaways
- 🚗 El Sistema de Producción Toyota (TPS) se centra en la eliminación de desperdicios y en proporcionar productos de calidad a tiempo.
- 🤖 El concepto de inteligente automatización, o jidoka, nació con las telares inventados por Sakichi Toyoda, el fundador del grupo Toyota.
- 🏭 La creación del modelo G, un telaro que se detendría automáticamente en caso de fallos, fue un avance significativo en la prevención de desperdicios y en la automatización.
- 🌐 La idea de fabricación just-in-time (JIT) surgió de las ideas de Sakichi y su hijo Kiichiro, quien llevó a Toyota al ámbito de la fabricación automotriz.
- 🔧 El TPS se consolidó durante la posguerra, con Taiichi Ohno desarrollando un sistema de producción más eficiente bajo la dirección de Eiji Toyoda.
- 📈 El sistema de Kanban, inspirado en las tiendas de supermercado de EE. UU., fue una innovación clave para la gestión de inventarios y la producción just-in-time.
- 🌟 La colaboración entre Toyota y General Motors para crear NUMMI en California demuestra la aceptación y éxito del TPS en el extranjero.
- 🚚 El sistema de entrega de partes (VAD) permite que los camiones viajen completamente cargados, minimizando los viajes y reduciendo el congestionamiento.
- 🔧 La implementación de medidas de jidoka en las líneas de montaje evita la producción de trabajo defectuoso y promueve la calidad.
- 🌐 El TPS se ha extendido globalmente y sigue evolucionando, pero sus conceptos fundamentales, como la mejora continua y la calidad, permanecen intactos.
Q & A
¿Qué es el Sistema de Producción Toyota?
-El Sistema de Producción Toyota es un método de fabricación que elimina el desperdicio y proporciona productos bien elaborados a los clientes de manera puntual, centrado en la inteligencia artificial y en la fabricación just-in-time.
¿Cuál es el origen del concepto de inteligente automatización, Jidoka?
-Jidoka proviene de las telas de Saritchi Toyoda, el fundador del grupo Toyota, que inventó telas que podían parar automáticamente en caso de un problema, evitando así el desperdicio.
¿Cómo ayudó el loom Model G a mejorar la eficiencia en la fabricación?
-El loom Model G permitió que un operario supervisara más de 30 telas a la vez, gracias a sus innovaciones en sensores y detenciones automáticas que evitaban el desperdicio.
¿Qué es la fabricación just-in-time y qué importancia tiene en el Sistema de Producción Toyota?
-La fabricación just-in-time es un concepto que busca eliminar el desperdicio haciendo solo lo que se necesita, cuando se necesita y en la cantidad necesaria, lo que maximiza la productividad y reduce los inventarios.
¿Quién fue Sakichi Sakichi y cómo contribuyó a la fabricación de automóviles en Toyota?
-Sakichi Sakichi fue quien llevó a Toyota a la fabricación de automóviles, estableciendo Toyota Automatic Loom Works y adaptando métodos de producción en masa estadounidenses.
¿Cómo surgió la idea de la fabricación just-in-time durante la Segunda Guerra Mundial?
-Durante la guerra, Taiichi Ohno, con el desafío de aumentar la productividad en un contexto de escasez de recursos, desarrolló un sistema más eficiente basado en la fabricación just-in-time.
¿Qué es un Kanban y cómo se utiliza en el Sistema de Producción Toyota?
-Un Kanban es una tarjeta que indica la necesidad de reponer partes consumidas por el proceso siguiente, asegurando que se hagan partes solo para reemplazar las que se han utilizado.
¿Cómo cambió la colaboración entre Toyota y General Motors la percepción del Sistema de Producción Toyota?
-La colaboración con General Motors, a través de la creación de NUMMI, mostró que el sistema de producción de Toyota era exitoso e inspirador, incluso en un contexto cultural y lingüístico diferente.
¿Cómo se implementa la inteligente automatización en las plantas modernas de Toyota?
-La inteligente automatización se implementa mediante sistemas de sensores en líneas de montaje que detectan y señalan problemas inmediatamente, así como medidas preventivas contra el trabajo defectuoso ideadas por los propios empleados.
¿Cuál es el impacto del Sistema de Producción Toyota en la mejora continua y la calidad de vida?
-El Sistema de Producción Toyota ha contribuido a la mejora continua en todas las fases de productos y operaciones, mejorando la calidad de vida al ofrecer productos de calidad a precios competitivos.
¿Cómo se ha adaptado el Sistema de Producción Toyota a las necesidades cambiantes?
-El Sistema de Producción Toyota ha evolucionado continuamente, adaptándose a las necesidades cambiantes y circunstancias, manteniendo sus conceptos fundamentales pero mejorando y refinando su implementación.
Outlines
🏭 Sistema de Producción Toyota
El primer párrafo aborda el Sistema de Producción Toyota, enfocado en la eliminación de desperdicios y la entrega oportuna de productos de calidad. Se menciona la importancia de la inteligente automatización y la fabricación just-in-time. La historia se remonta a la invención de telares por Sakichi Toyoda, quien también creó la lona automática G, que incluía innovaciones para detener la máquina en caso de un error y así prevenir el desperdicio de materiales. Sakichi reemplazó el carácter de 'movimiento' en 'jidoka' por uno que significa 'trabajo de valor añadido', subrayando la importancia del elemento humano en la automatización. Además, se introduce el concepto de fabricación just-in-time, iniciado por Kiichiro Toyoda, quien llevó a Toyota a la fabricación automotriz y trabajó en la mejora de la producción en masa.
🚗 Desarrollo del Sistema de Producción Toyota
El segundo párrafo habla sobre cómo Kiichiro Toyoda, tras visitar Estados Unidos y ver el potencial del mercado automotriz, decidió entrar en la industria. A pesar de las dudas, desarrolló un prototipo de automóvil y comenzó la producción. Posteriormente, durante la Segunda Guerra Mundial y después de la guerra, el sobrinito de Kiichiro, Eiji Toyoda, y Taiichi Ohno, trabajaron en la mejora de la producción. Ohno implementó el sistema Kanban para que los procesos produjesen solo lo necesario y cuando fuera necesario, lo que maximizaba la productividad y minimizaba los inventarios. Este sistema fue fundamental para el desarrollo del Sistema de Producción Toyota, que se convirtió en un estándar para la industria manufacturera.
🌐 Influencia Global del Sistema de Producción Toyota
El tercer párrafo destaca cómo el Sistema de Producción Toyota ganó reconocimiento mundial después de la crisis del petróleo de 1973, cuando Toyota se recuperó más rápidamente que otros fabricantes. General Motors se asoció con Toyota para crear una empresa conjunta en California, lo que resultó en una cooperación exitosa y un reconocimiento de la calidad. El sistema se ha implementado en plantas modernas de todo el mundo, con un enfoque en la entrega de partes just-in-time y la inteligente automatización para minimizar los inventarios y maximizar la productividad.
🌟 Legado del Sistema de Producción Toyota
El último párrafo enfatiza el legado del Sistema de Producción Toyota, cuyo fundamento fue establecido por Sakichi Toyoda con la inteligente automatización y Kiichiro Toyoda con la fabricación just-in-time. Con la implementación sistemática de Taiichi Ohno y el apoyo de Eiji Toyoda, el sistema ha continuado evolucionando para satisfacer las necesidades cambiantes. El compromiso de Toyota con la mejora continua en todas las fases de los productos y operaciones ha contribuido a mejorar la calidad de vida de las personas en todo el mundo.
Mindmap
Keywords
💡Sistema de Producción Toyota
💡Integración Inteligente
💡Fabricación Just-in-Time
💡Sakichi Toyoda
💡Kiichiro Toyoda
💡Taiichi Ohno
💡Kanban
💡Desarrollo de Prototipos
💡Mejora Continua
💡Calidad de Vida
Highlights
Toyota Production System focuses on reducing waste and delivering quality products timely.
Intelligent automation and just-in-time manufacturing are core concepts of the Toyota Production System.
Jidoka, intelligent automation, originated from Sakichi Toyoda's loom inventions.
Sakichi Toyoda's loom innovations increased efficiency and reduced manual labor.
The Model G loom was a breakthrough in preventing waste with automatic stop mechanisms.
Jidoka emphasizes human value-added work in automation.
Just-in-time manufacturing was pioneered by Kiichiro Toyoda to eliminate waste in production.
Kiichiro Toyoda established Toyota's automobile manufacturing and adapted mass production methods.
Taiichi Ohno developed a more efficient production system post-World War II.
Kanban system ensures parts are made only to replace those consumed.
The Toyota Production System gained global attention after the 1973 oil crisis.
General Motors and Toyota established a joint venture, NUMMI, applying the Toyota Production System.
The system operates with trucks delivering parts just-in-time to minimize traffic and inventory.
Kanban cards are used to signal when parts need to be replenished.
Jidoka continues to prevent waste by building quality assurance into every process.
The Toyota Production System is founded on Sakichi Toyoda's innovations and Kiichiro Toyoda's manufacturing principles.
Taiichi Ohno and Eiji Toyoda's leadership contributed to the system's evolution and global adoption.
The Toyota Production System is committed to continuous improvement in all aspects of product and operations.
Transcripts
consistently crafted cars roll off the
assembly line in a smooth flow they are
alive with the spirit of providing
people with quality products through
conscientious manufacturing and
continuing research and development this
is the Toyota Production system where
manufacturers eliminate waste to provide
customers with well-made products in a
timely manner
[Music]
at the heart of the Toyota Production
system are the concepts of intelligent
automation and just-in-time
manufacturing let's explore the history
of that system which has transformed
manufacturing around the world the
concept of intelligent automation called
jidoka originated in looms invented by
Sakichi Toyoda the founder of the toyota
group waving traditionally had been a
very manual kind of work
[Music]
the Weaver fed the horizontal yarn back
and forth between the vertical yarns
[Music]
Sakichi had watched his mother working
at a manual loom and thought of ways to
make weaving easier
[Music]
[Applause]
he invented an original wooden hand loom
in 1890 his loom was easy to use and
nearly fifty percent more efficient than
previous looms the operator could move
the yarn guide back and forth with one
hand and feed in the horizontal yarn
simultaneously Sakichi then went to work
on power looms in 1896 he created
Japan's first paladin and he continued
making one improvement after another in
1924 Sakichi and his son Kyoto achieved
a historic breakthrough they created the
world's first high speed loom that fed a
new wept the horizontal yarn reliably
without interrupting work let's take a
look at a feature of their breakthrough
non-stop loom the Model G traditional
looms wasted material on fabric like
this when one of the vertical warp Aeon
snapped as often happened to prevent
that waste Sakichi and kikyo arranged
thin metal floaters over the vertical
yarns a floater would slip down and stop
the loom if it's yarn snapped these
automatic stop innovations for
preventing a waste were absolutely
remarkable sake G had created
sophisticated sensors and he had done
that without the benefit of the
electrical and optical technology we now
take for granted
[Music]
[Applause]
his innovations eliminated the need for
an operator to watch over each limb
continuously one operator could oversee
more than 30 looms the model G captured
a great deal of attention in Europe and
the United States so saachi's advances
resulted in machines that would stop
automatically if problems occurred that
would not produce defective work and did
not oblige people to serve as monitors
the middle character in the Japanese
word for automation judoka is dull for
movement but Sakichi replaced that
character with one that means
value-added work
note the additional element on the left
side which represents people sake cheese
judoka put the human element into
automation the other core concept in the
Toyota Production system is just-in-time
manufacturing this concept originated in
the ideas of Sakichi sankichi doe who
led Toyota into automobile manufacturing
along with working with his father on
the model G moon he judo helped put in
place a mass production system he
established Toyota automatic loom works
in 1926 and introduced American assembly
line methods to produce the Model G loom
[Music]
cachito traveled to Europe and North
America in 1929 to find licensees for
his company's automatic loom technology
he was amazed at all the vehicles and
roads in the United States and he
resolved to begin developing automobiles
people tried to dissuade a Cheeto they
said that Japan didn't have either the
technology or the economic foundation
for a viable car industry but he ignored
their doubts and set up a shop in a loom
factory to develop small engines he
undertook the risk of investing in
expensive precision equipment
in 1935 his team created a passenger car
prototype the Toyota model a1 in the
following year the first Toyota
passenger car went into production as
the Toyota model a a cachito
incorporated his automobile operations
in 1937 and began work on a vehicle
plant
he refined American mass production
methods for his plant and developed the
beginnings of just-in-time manufacturing
[Music]
the idea was to eliminate waste by
making only what was needed only when it
was needed and only in the amount needed
making quality cars of satisfactory
performance required an all-out effort
and cachito was moving to refine
just-in-time manufacturing further at
the outbreak of world war ii in 1941
interrupted his efforts after the war
cachito passed on his dream to his
cousin AJ he instructed AG to bring the
company up to u.s. standards of
Technology within three years that was a
daunting task u.s. productivity in
automobile manufacturing was eight times
higher than Japan's entire a was short
of equipment and capital so raising
productivity was a pressing issue AG
assigned a machine shop manager by the
name of taiichi ohno to develop a more
efficient production system
the two men looked for ways to raise the
value-added productivity of every worker
they did that by putting sake cheese
jidoka concept to work throughout their
operations they also looked for other
ways to stretch their limited resources
of equipment and capital they did that
by putting kiichi toes just in time
concept to work systematically
[Music]
oh no took a cue from the US supermarket
he made each process the customer for
the proceeding process in traditional
manufacturing processes delivered parts
to the following processes regardless of
what was actually needed Ono devised a
completely new kind of system processes
used Kanban cards removed from parts
they had consumed to withdraw parts from
the preceding processes Kanban on the
parts arrayed by processes came off when
the following processes withdrew the
parts they became instructions to make
additional parts the Kanban flow ensured
that processes made parts only to
replace parts actually consumed by the
following processes
[Music]
active cooperation by the people in the
workplace would be essential to Ohno
system but at first people were
reluctant to give up their old ways of
doing things
[Music]
bono took the initiative he went into
the workplace and taught people how to
use his system
Aug tortoise supported Ono
enthusiastically in putting the new
production system in place
[Music]
a new production system gradually took
shape on the foundation of just-in-time
manufacturing and judoka intelligent
automation as the Toyota Production
system it became a standard for
manufacturing industries the Toyota
Production system gained global
attention after the oil crisis of 1973
Toyota recovered more quickly than other
automakers from the crisis and its
production system received much of the
credit for that resilience General
Motors Corporation approached Toyota
about setting up a joint venture to make
small cars in the united states the two
companies set up new united motor
manufacturing incorporated in california
in 1984 differences in language and
culture presented big challenges but the
spirit of making things well knows no
borders people accepted the Toyota
Production system and the Toyota GM
joint venture became the highest ranked
automobile plant in the United States
for quality it became a symbol of
successful industrial cooperation
between Japan and the United States
a book published by the Massachusetts
Institute of Technology hailed the
Toyota Production system as the machine
that changed the world today the Toyota
Production system has gained a worldwide
following let's see how the system now
operates in the world's most modern
automobile plants
[Applause]
the trucks that deliver parts to the
plants carry a variety of items in each
load VAD allows each truck to travel
fully loaded which minimizes trips and
thus reduces traffic congestion
[Music]
forklifts carry the parts unloaded from
the delivery trucks to racks along side
the assembly lines
[Music]
when people on the assembly line used
the parts they removed the attached
Kanban cards the Kanban that get picked
up regularly and sorted the delivery
truck drivers pick up the convent for
their companies or companies before
leaving
back at the suppliers plant the Kanban
become orders for withdrawing additional
parts sorting arranges the Kanban
according to area in the plant
shipping personnel exchanged the Kanban
and empty boxes for full boxes
the production processes in the plant
make additional parts only to replace
parts that have been withdrawn that
prevents the wasteful buildup of
inventories when the shipping personnel
have gathered a full truckload of parts
a truck carries the parts to the vehicle
plant Kanban thus linked Toyota plants
with suppliers plants as well as linking
the processes inside the Toyota plants
just-in-time manufacturing minimizes
inventories eliminates waste and
maximizes productivity at all the plans
that participate in the Toyota
Production system judoka intelligent
automation also continues to play a big
role in the system on automated
machining lines numbered lamps light up
to call attention immediately to any
problems detected by sensors
on assembly lines the employees
themselves have devised countless judoka
measures to prevent defective work so
saachi's concept continues to prevent
waste
the idea is to build Quality Assurance
into every process and it works
[Music]
the foundation for the Toyota Production
system has been established by Saki
cheese judoka intelligent automation and
his son kiichi toes just-in-time
manufacturing
[Music]
taiichi ohno and others put those
concepts to work systematically with the
strong support of Ag Toyota and his
passion for manufacturing
the Toyota Production system continues
to evolve in response to changing needs
and circumstances but the fundamental
concepts are eternal
including Toyota's commitment to
continuing improvement in every phase of
products and operations those concepts
underlying contribution to enhancing the
quality of life for people everywhere
[Music]
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