What is TPS?
TPS stands for Toyota Production System — a production philosophy developed by Toyota to eliminate waste, safeguard quality and shorten lead times.
TPS is the foundation of LEAN manufacturing and combines people, processes and culture into a single continuous improvement model.
The system was developed in the 20th century by Taiichi Ohno and Eiji Toyoda, and has influenced how factories, logistics and even hospitals are organised worldwide.
🧱 The two pillars of TPS
TPS is built on two core principles:
| Pillar | Description |
|---|---|
| Just-in-Time | Make only what is needed, when it is needed, in the right quantity |
| Jidoka | Stop immediately when a problem occurs (automation with a human touch) |
Together they ensure smooth processes with high quality and minimal waste.
🎯 Goal of TPS
- Eliminate loss and waste
- Optimise production based on demand (pull)
- Build quality into the process itself
- Actively involve employees in improvements (Kaizen)
🧺 The 7 wastes of TPS
| Waste (Muda) | Description |
|---|---|
| Overproduction | Making more than is needed |
| Waiting | Time lost to waiting |
| Transport | Unnecessary movement of products or people |
| Overprocessing | More work or quality than required |
| Inventory | Too much raw material or work-in-progress |
| Motion | Unnecessary physical activity |
| Defects | Products that have to be reworked or scrapped |
(→ Later extended to 8 wastes in LEAN with “Skills” added)
🔧 Well-known TPS methods and tools
| Tool | Explanation |
|---|---|
| Heijunka | Levelling production to prevent overload |
| Kanban | Pull system based on visual signals |
| Andon | Visual signalling for deviations or faults |
| Kaizen | Continuous improvement from the shop floor |
| Poka Yoke | Building in error-proof solutions |
| 5S | Order and tidiness in the workplace |
| Takt Time | Aligning the rhythm of production with customer demand |
🏭 TPS in practice
- Automotive industry: Flexible production lines, minimal buffer stock
- Healthcare: Shorter waiting times, standardisation of activities
- Distribution: Just-in-Time replenishment of stores
- Construction and installation: Prefabricated parts based on demand
🔗 TPS vs. LEAN
| TPS | LEAN |
|---|---|
| Developed by Toyota | Derived from TPS, more broadly applied |
| Deep corporate culture | Methodical framework with tools |
| Based on respect and discipline | Focused on value, flow and improvement |
✅ Benefits of TPS
- Better product quality through built-in error detection
- Shorter delivery times and greater flexibility
- Lower energy and material consumption
- Employee participation and motivation
- Globally proven effectiveness in production and logistics
📌 In summary
TPS is Toyota’s original production system, which forms the basis for LEAN. It revolves around quality, flow, continuous improvement and respect for people.
Want to apply TPS principles in your production environment or learn how LEAN grew out of it? Request a TPS vs. LEAN overview or a Kaizen guide!