LEAN+: Toyota System


Toyota Production System (TPS) follows the principle that use of resources, both human or material, for any purpose other than the adding of value for the product/service is a form of waste which should be eliminated. It is focused on an never-ending optimization of processes through continual improvement of all those elements which may result in an unsatisfactory performance. Careful analysis of processes, identification and separation of “value-added” from “non-value-added” activities, elimination of waste at all incremental stages of product/service processing and streamlining of the process flow, its throughput is maximized and the quality of delivered products and services is improved.

Through identification of various forms of “muda” (“waste”) such as unnecessary movement and/or transportation of goods and personnel, idling of personnel, handling damage, poor quality, process unevenness, etc., and persistent elimination of their root causes such as defects, rework of defective products, excessive inventories at all stages of processing and product life cycle, etc.

TPS identifies the 7 (seven) types of “muda” (or “waste”):
– Muda of Correction – rework of produced goods, fixing of mistakes
– Muda of Overinventory – overstocking at any stage of processing, waiting for the next process
Muda of Overproduction – production of too much or too early
Muda of Waiting – People are idle, waiting for something
Muda of Motion – Unnecessary movement/action of personnel
Muda of Conveyance/ Transportation – Non-productive transfer of goods during processing
Muda of Processing – unnecessary processes that don’t add value to the product or service

The above forms of waste not only do not add value to the products and services but may result in waste of human talent, irreversible loss of enthusiasm and damage permanently the morale of personnel.

Quexx LEAN+ program offers training, consulting and implementation support for these elements of Toyota Production System which were carefully selected from our Quality Management “toolbox” and customized to address your specific needs, business circumstances and work environment. Our consultants have extensive experience in introduction of LEAN techniques. Our consultants were trained by Toyota Motor Corporation and have hands-on experience in introducing efficient and effective methodologies of TPS.

We will:
– Deliver comprehensive training suitable for all levels of your personnel
– Discuss common forms of waste which does not add value to the products and services
– Share our experience in implementing effective CAPA ( corrective and preventive action) methodologies
– Promote further improvement through potential introduction of “LEAN” Techniques such as Continuous Improvement, Visual Communication, Just-In-Time, Error-proofing, Autonomation, Production Leveling, Effective Reporting, Go-and-See Management, and more…

Quexx International Ltd. consultants are dedicated to providing you with exceptional quality services. Extensive experience and expertise of our consultants offers training and consulting services tailored to suit your needs and your unique work environment. QUEXX consultants were trained by Toyota Motor Corporation, a World leader in Continuous Improvement and have hands-on experience in implementing LEAN techniques of Toyota Production System.

For more details please refer to our Training Guidelines.

Explore our Cruise-and-Learn™ Program.

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