What is Kanban?

Kanban literally means “signboard” in Japanese. It was created by Toyota as a key element in achieving their Just-In-Time manufacturing philosophy. The Just-In-Time manufacturing process was created to reduce lead times and operating costs. Lead times are reduced by eliminating wasted time caused by overproduction or unnecessary production. Operating costs are reduced by eliminating unnecessary […]

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The Toyota Way Chapter 9: Principle 3: Use “Pull” Systems to Avoid Overproduction

“Kanban” is a scheduling system for lean and just-in-time (JIT) production. Kanban is a system to control the logistical chain from a production point of view. Problem areas are highlighted by reducing the number of products in circulation. As per figure 9-1 – Parts in the assembly plant are replenished directly from the supplier. Through […]

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The Toyota Way Chapter 8 – Principle 2: Create Continuous Process Flow to Bring Problems to the Surface

“If some problem occurs in one-piece flow manufacturing then the whole production line stops. In this sense it is a very bad system of manufacturing. But when production stops everyone is forced to solve the problem immediately. So team members have to think, and through thinking team members grow and become better team members and […]

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The Toyota Way Chapter 7 – Principle 1: Base Your Management Decisions on a Long-Term Philosophy, Even at the Expense of Short-Term Financial Goals

“The most important factors for success are patience, a focus on long-term rather than short-term results, reinvestment in people and plant, and an unforgiving commitment to quality” – Robert B. McCurry, former Executive V.P., Toyota Motor Sales This chapter of the Toyota Way, was hard hitting and to the point. We found as a business […]

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The Toyota Way Chapter 6 – The Toyota Way in Action: New Century, New Fuel, New Design Process – Prius

“Creativity, Challenge and Courage: the Three C’s” – Shoichiro Toyoda, former President, 1980s The Prius design process in the early 1990s involved Toyota following its first principle: “Base your management decisions on a long term philosophy, even at the expense of short term financial goals.” Toyota’s short term financial situation was exceptional at the time […]

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The Toyota Way Chapter 5 – The Toyota Way in Action: The “No Compromises” Development of Lexus

“Even if the target seems high as to be unachievable at first glance, if you explain the necessity to all the people involved and insist upon it, everyone will become enthusiastic in the spirit of challenge, will work together and achieve it.” – Ichiro Suzuki, chief engineer of the first Lexus. The above quote summarises Chapter […]

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