Assignment Sample on Lean Integrated Design and Production
Introduction
The Toyota Production System uses an approach of Lean Production to increase the efficiency and eliminate waste of its car manufacturing system. Toyota uses this method of production for improving its integrated design, control and production process. Several companies have adopted the process of Lean in their operations and achieved greater success in their respective industries. In this report, Lean methods will be planned and implemented in the Design process and critical evaluation of the same will be done. Insights will be gained about using Lean in different areas of operations of any business for achieving maximum efficiency.
1. Lean Production Principles and Theoretical Benefits of Lean
1.1 Principles of Lean Production
Lean manufacturing as well as Lean thinking has been adopted by several companies to achieve success in the modern time of global competitive markets (Ganesh, 2021). The lean principles followed by Toyota Production system for sustained growth and success can be identified as follows.
1.1.1 Value Identification
Value Identification is the first and foremost step among the Lean principles practised by Toyota as well as other adopters of this method. It helps a company to determine its operations according to its value proposition. A specific product is valuable in the market when it can effectively solve some problems of the customers and offer them a proper value for the money they paid to buy the product. Toyota takes good care of this aspect using lean thinking in its operations. Its design and production methods are mostly guided by two areas of focus: “the particular need of customers” and “elimination of features or services that are presently of no use to customers” (Roriz et al. 2017). Toyota uses this principle in order to reduce waste generated from its operations, focussing only on the items that they require to build great automotive for the customers.
Toyota often uses Design for Six Sigma (DFSS) in order to ensure lean production in all its operations. Six Sigma is used to reduce defects in the design and production process, thus, improving the quality of manufacturing. Value identification of customers is conducted by surveys and feedback from users and information gathered is used to modify operations in order to manufacture cars tailored for its customers (Azadeh et al. 2017). Such lean principle increases efficiency of the process, improves the quality of production and helps the company to build a great reputation among its customers.
1.1.2 Value Stream Mapping
Value Stream Mapping is the process of visualising the complete product life-cycle of the product, from designing to usage and disposal. It is the second step of Lean principle practised by companies influenced by the Lean method. After receiving relevant information from the value identification phase, collected data is used to conceptualise and design automotive that can fulfil the needs of customers (Wagner et al. 2017). A value steam is thus generated that can show the steps of designing the product, determining the period of use and steps of disposal. Different Value Stream Mapping tools are used in this process to increase the efficiency of the Lean manufacturing process. This process helps to identify and eliminate any area of a product that does not add value to the customers.
1.1.3 Creating Flow
The Lean principle that comes next to value stream mapping is creating flow in the operations of production. A company needs to take care of each and every aspect that contributes to smooth flow of operations ensuring completion of scheduled tasks within an estimated time. Work floors and the systems associated in the production are strategically organised in order to ensure efficient material handling. A company requires uninterrupted flow from production to shipping in order to achieve higher profitability and better optimisation of the business operations (Mrugalska&Wyrwicka, 2017). Inventory management of the company improves due to smooth flow of operations and reduces wastage of essential resources.
1.1.4 Pull-based Production System
The fourth Lean principle used by Lean adopters is formation of a Pull-based production system. In most companies, the traditional method of production and supply is used to meet the demands of customers, by pushing products from production to distribution stage. One significant problem that was identified by Lean thinkers with this method, was a long period of Work-in-Progress. In order to reduce such problems, a Pull-based production system was introduced that pulls orders from customers from the shipping department and guides the production department to increase or decrease the rate of production (Abbassinia et al. 2020).
Lean manufacturing frameworks such as Kanbanare used to ensure an effective pull-based production system in a company. A Pull-based production system helps to reduce cost of inventories, increase output and eliminate chances of overproducing or under producing products. Tools such as Kanbanallows project members to view progress of every part of the work in real-time, thus improving decision-making and reducing errors caused due to long periods of Work-in-Progress (Leyh et al. 2017).
1.1.5 Seeking Perfection
The fifth and the last Lean principle used by Lean companies is seeking perfection of its products being manufactured. The Lean companies develop a culture at the workplace that promotes seeking perfection in each of the activities performed. The philosophy of Kaizen is often used in those companies to ensure better productivity through incremental changes. It mostly encourages employees at the technical as well as managerial level to add small changes that will positively affect the quality of production. This principle is also used to reduce operational costs over long-term and increase brand value of a company (Deshmukh et al. 2017). A predominant belief is practised by perfection-seeking Lean companies that changes in the internal environment of a company will help to deliver better products to its customers.
1.2 Theoretical Benefits of Lean
The theory and practice of Lean manufacturing both concentrates on one single objective – Maximisation of Customer Value with lesser resources. Such a practice is immensely beneficial to a company in terms of profitability, decreasing waste generation and building greater brand value among its customers. The company can make better decisions to satisfy the interests of stakeholders as well as consumers. Lean thinking helps in a development of employee culture that is highly engaging in nature. It helps to determine the product life-cycle with more accuracy and expectations of the customers are studied to provide better value. Incremental changes are constantly made to streamline its process to achieve maximum efficiency (Zhuravel, 2019). A sense of perfection is developed among the workers of the company and the product users, resulting in building a greater brand image.
Lean philosophy does not promote settling the business with existing products and evaluates the market for more opportunity. It encourages managers to look for patterns of change in demand of customers and identify the potential ones. According to Soliman (2017), developing products that can adapt to the changing circumstances gives the company a higher competitive advantage over other competitors in the same industry. Expectations from customers are also increased in the due process as customers become aware of the perfection mindset of the companies using Lean philosophy, resulting in production of more innovative products.
2. Context explanation and Critical Evaluation of the Current Process
2.1 Context of Design Process
The availability of specific products in a market is determined primarily by the demand of customers. Products are manufactured in order to satisfy some particular needs of a market and the consumers. Identification of the needs of customers is the most significant area of any business that is willing to offer solutions to those problems. However, identification of needs is required to be followed by a conceptualisation and design of a product that can solve the problems faced by the consumers. Design has become a primary area of concern for any manager as it will influence the subsequent manufacturing and distribution process (Powell &Reke, 2019).
The application of Lean thinking in the design process is the topic of study in this report. The areas of design should be classified into different parts in order to understand the scope of applying Lean philosophy in designing the desired product. Design takes care of the form and function of the product to be manufactured. As narrated by Kolberg et al. (2017), the customers are also interested to experience better feel and comfort while using any product that they desire. Several design considerations are used in designing any particular product, depending on its type of functionality.
The scope of applying Lean manufacturing methods can be found in design considerations as described below. Structure for Design is an important area of design consideration that helps designers to select such a medium of design that will be appropriate for the manufacturing of the products. The Value Identification principle of Lean philosophy can help the designer in the decision-making process. Design of flow of operations to achieve the desired objective will be immensely benefited by the philosophy. Information about customer preference and price that they are willing to pay for a desired product are taken into consideration. Such information helps to construct a budget plan for manufacturing and distributing the product to the customers. Reduction in operational costs without any compromise in the product quality is ensured in the design phase using Lean principles (Tortorella et al. 2020).
Performance is one of the major design considerations while attention is also given on safety features and ergonomics of the manufactured product. Safety standards are maintained along with giving an appealing look to the manufactured products. It increases the feel component of any product to its users. Information can be gathered from customers in the form of user stories and product reviews and incremental changes can be done to the product to give it the final shape. Customer buying behaviour is studied to form a better idea while understanding the psychology of humans interested to buy any particular product. Improvement is noticed in all areas of design found in business organisations by using Lean principles (Al-Shawi and Manhal, 2020). Awareness of the technology used in the products and ease of use are also considered in design in order to increase customer engagement.
2.1.1 Design Strategy
Design strategy can be defined as developing a plan of approach for designing desired products. Attention is given to production and development of Minimum Viable Product for maximum profitability of the company. Value Sensitivity is another aspect of design considered in developing a design strategy using Lean manufacturing methodology (Dante et al. 2019). It gives an idea of societal values and cultures that influence buying of any product existing in the market. Insights from such analysis are taken to develop new products that are in accordance with societal values of the customers. Modern trends and preferences are studied thoroughly using Lean techniques to provide better value to the customers. Design strategy also takes into account the dislikes of the customers in order to eliminate features from a product that will not appeal to the senses of customers.
Design strategies using Lean philosophy creates value for customers in the design and execution phases with designs that are influenced by their choices. However, Lean thinking allows designers to make occasional speculative designs to offer some variety to customers. Defects in design or impracticality of design are reduced using the principles as used by Toyota Production Systems. Car design was improved to suit the preferences of the customers and they got more value in terms of appeal and performance from the vehicles. Design strategy focussed heavily on the effectiveness of the processes involved in manufacturing and any unnecessary operation was removed to increase productivity. Value Stream mapping immensely helped in designing the sequence of operations ensuring better flow and effective use of resources required for manufacturing (Mourtzis et al. 2017).
2.2 Critical Evaluation of the Current Process
Design process is considered for evaluating the use of Lean production methods in business. Different aspects of design are considered that may be subjected to modification using the selected method of production. As design is an integral area of product development, steps are taken to improve the efficiency of the design. Ergonomic factors such as ease of use are considered to develop better products that can function suitably with minimum human intervention. Importance is given to reduction of waste by applying different methods of waste management. Such methods help to eliminate waste due to overproduction, transportation, excess inventory, unnecessary motion, over processing and others. According to Butollo et al. (2019), it helps the company to identify non-value adding operations and strategically eliminate them from its set of operations to achieve the desired goals. Most companies in the automotive industry are shifting towards using Lean philosophy in their operations.
A critical evaluation of the design process using Lean methodology shows that seeking perfection by applying incremental changes in design improves the overall productivity of a company. Continuous improvement methods of Kaizen are used to better the quality of each component involved in the design of the entire product. The pull system also helps designers to create better designs based on the demand information gathered from shipping departments of a company. Flow of operations helps in time-effective manner leads to faster delivery of products to the consumers. This phenomenon leads to an increase in sales of a company, generating a huge amount of revenue each year. Optimisation of the whole base of operations is comparatively easier using Lean principle, allowing the managers more flexibility to manage operations (Kehr and Proctor, 2017). Use of a long-term philosophy helps to build a positive culture among the employees.
In recent times, it is seen that most automotive companies are moving towards automating most of its operations. The “Automation with Human Touch” of Lean production is used as an important area in design practices. Companies operating according to this philosophy only depend on technology that are thoroughly examined and found to be reliable. This involves automating specific areas of production that are absolutely necessary. Moreover, Lean philosophy encourages the company to become a learning organisation and its people to be lifelong learners, thus increasing the quality of design of the manufactured products (Yamamoto et al. 2019).
3. Description of systematically developed target process
Systematic development of the target process is essential as such development ensures success of operations in any selected process. The process selected here for the purpose of studying and evaluating is the implication of using Lean philosophy in design. Initially, the value identification phase of the design is required to be specified. According to Sunder et al. (2020), design of a product is only possible when there is sufficient information about the requirements of the customers from the manufactured products. The designers are expected to organise the activities of the design department in order to design a minimum viable product that is going to be produced and distributed for retailing.
A value stream mapping is required to be fixed in the design phase of a product that is under development. It will help the managers and employees to understand the direction of flow of operations and estimated time for completing each of the tasks. A timeline is prepared and maximum waiting times for each operation is included in the timeline. The value stream map will also contain defect rates for any activity and deviation from that number must lead to thorough inspection of the process. A backward work scheduling is included in the value stream maps in order to prioritise activities to ensure timely delivery of final product (Das, 2018).
The next step in systematic development of the target process is to collect information about process timings and optimise the rest of the functions accordingly. Different factors such as Process Cycle Time, Defects per Day, Batch Size, Changeover Time and First Pass Yield are identified and filled up for data processing. The information is used to calculate the total time required from production to shipping of finished products (Pastore, 2017). Queuing time is considered to direct activities to reduce wastage of time. It mainly focuses on moving a single work piece through the production line for one specified operation one at a time in order to ensure quality of the product. Reduction in lead-time offers the company a competitive advantage over other potential players of the automotive industry.
Process data filling and analysis is followed by measuring percentage of value addition to the system using Lean production methodology. Value addition measurement is done to identify areas of compliance and regulation that a customer is willing to pay for. Value-added and non-value added features of a design are identified in this phase and strategically eliminated to reduce cost and increase the economic viability of the product. According to Ko and Kuo (2019), information from value stream mapping and value addition measurement are immensely helpful for Supply Chain Management, Quality Control and other departments. Detailed information about value-addition also helps the company to gain confidence of investors in securing funds.
Strategic development of the design process includes the effective interpretation of Value Stream Map in order to optimise the operations for maximum profitability. A pictorial view of the complete sequence of operations helps managers to identify bottlenecks in projects and remove them. Processes with unusually longer set up times are modified or alternative methods are found out. Detailed information about the current state of operations are collected and future state of operations can be predicted due to inclusion of customer data in the maps. Interpretation of Value Stream Map also leads to identify the most suitable methods of production generating the least amount of wastes, reducing the operational costs and increasing the quality as well as the profit margin (Moro et al. 2019).
TPS (Toyota Production System) is based on the philosophical purpose that helps to improve decision making and problem-solving procedure. Generation of value of customers is considered as a starting point and analyzing every function of a company in terms of ability helps to achieve the goals and objectives as soon as possible. This company follows redesigning the work process that helps to improve the continuous flow of the company. The company always wants to improve the setup time as well as the company always efforts on reducing length of process. As suggested by Hoellthaler et al. (2018), the company tries to reduce wastes as well as shortages of products. Toyota’s production system is based on just in time and jikoda and it is considered as supercharged production in the world.
Evidence has suggested that TPS is a source and outcome of a powerful lean six sigma team. It usually helps to provide high-performance culture as well as the strength of the company is increased by this TPS. As narrated by Toma&Naruo (2019), it is one of the best reasons for the high performance of the company as well as employees both. The customer satisfaction, customer numbers, and profitability of the company will be increased by this innovative Toyota production system. The six sigma system is made by TPS and it is one of the best reasons for developing excellent quality products.
A recent report has suggested that the TPS system consists of two different pillars such as jidoka and just in time. Improved quality is contemplated as very beneficial as it helps to improve TPS more. It has found that material, idle equipment, time, and inventory are some of the forms of elimination of wastes (Powell et al. 2018). As normal, many companies have approximately 70% to 90% wastes of total resources; however, TPS has low elimination of wastes rather than other companies.
The six sigma strategies of Toyota production system are described in this study and these are as below.
Decreased setup times
The majority of setup time is wasteful and all of these do not provide value to business. This strategy of TPS includes providing training to employees, handling products though using carts and others, which helps to manage the setup times from months to months and minutes.
Minimum production
A large amount of manufacturing process leads to huge amount of setup costs, capital costs and large inventories, and huge defect costs. This strategy helps TPS to manage production within low operating costs and low handling costs. The profits along with revenues will be improved by this strategy (Tabares, Robles-Cárdenas &Romainville, 2017).
Workers empowerment and involvement
Evidence has suggested that Toyota divided its employees into several stages on account of handling all manufacturing works successfully. Team members help to manage all internal factory work with patience and entire warehouse works is managed properly by this strategy (WAHAB, MUKHTAR & SULAIMAN, 2017).
4. Practicable implementation plan
The implementation plan is necessary for any business as it can help to develop a better understanding of new products and designs. In order to have a corporate TPS system with more viability, a proper implementation plan is necessary. It can be beneficial to evaluate business prospects and authentication of data can be possible. Besides that, management of new innovation can be possible with the help of such strategic views, and competency of business can be increased (Veres et al. 2018). As a result, it becomes possible to gather more efficiency as well as fulfillment of customers demand can be possible in any situation.
A table is given below to show the process of implementation in detail and the high validity of data can be justified through such process.
| Plans | Time | Significance |
| Deliverance of training for all employees | 6 months | Providing training to all employees will improve the work performance as well as reduce wastes. |
| A risk assessment by using drone technology | 2 months | Drone technology will be beneficial as it can help to reduce the risks of overproduction as well as misproduction. |
| Analysis of monthly budget with the help of accounting software | 1 month | Financial issues and liquidity will be improved by analyzing monthly budgets through the help of accounting software. |
| Development in sales strategy | 3 months | Sales strategy can help to promote products in the market successfully as well as the profits of the company will be enhanced in a significant manner. |
| Identification of competitors (Cochran Foley & Bi, 2017) | 5 months | It can be one of the most beneficial plans, which can help to enhance the competitive advantages of the company. Besides that, the market position of the company as well as rivalry threat will be understood by this plan. |
| Enhancement in funding prospect of new strategy | 7 months | Funding enhancement in the prospect of new strategies can help to improve the manufacturing process as well as the products of TPS (Wagner et al. 2017). |
Table 1: Implementation Plan
(Source: Wagner et al. 2017)
Six major planning schemes will be followed by the Toyota administrative department to be strategically fit and development in future prospects can be possible.
Training
Training can be considered as a necessary component that can help the employees of Toyota to understand new technology and reliability of business processes can be possible. It is evident that workers are not able to understand new processes of business and this will be effective to make business slow due to lack of productivity. There is a plan to give both online and offline training for workers twice per week and the entire process will be accomplished within the next six months (Satolo et al. 2017). As a result, understanding the system as well as its implication can be transparent for them and suitable business exploration can be possible with high efficiency.
Assessment of risks
Risk assessment is an integral part of any project as it can help to deliver a better understanding of potential causes of damages and future stability can be acquired. As opined by Rewers et al. (2017), in order to implement such a strategy, drone technology can be used and the entire measurement will be completed within the next 2 months just after training. Assessing of risks can help in potential searching of all products and reliability of company data can be acquired. Moreover, deliverance of safety for all the customers as well as internal stakeholders can be managed with high efficiency.
Analysis of budget
Budget analysis is a prime strategy that can help the financial department of any organization to gain real-time data about the fact. Accounting software will be implemented within the next 2 months of risk assessment for making business strategically correct. The introduction of software can be beneficial to develop business views and correct data feasibility can be possible (Alhamdi et al. 2019). In addition, budgetary in-flow in business can be possible with the help of technological systems in the Toyota business environment. Management of financial issues can be solved with high potency with the help of such type implementation in the business process.
Development of sales strategy
Development, as well as improvement of sales strategy, is considered as very beneficial as it is strongly related to the financial position of the company in the automotive industry. In the word of Richardson & Richardson (2017), this plan can help to maintain the cash flow and liquidity of the company in a significant manner. It is evaluated that the operating cost will be reduced with this. One of the most important factors, the sales strategy can help promote products successfully and the numbers of customers will be increased by this sales strategy. Furthermore, the profits and revenues of the company will be enhanced by this sales strategy within 3 months.
Identification of competitors
Competitors can decrease the position of the company as well as the profits along with revenue are decreased by competitors. Therefore, the identification of customers will be feasible as well as suitable for TPS as it will help to improve the competitive advantages of the company as much as possible. Besides that, this plan can help to understand the business position as well as sustainability position Toyota production process (KorchaginDeniskina&Fateeva, 2019). The entire plan will be used for 5 months and within 5 months; it will improve the competitive advantages of the company. Usually, many companies provide products at low prices as well as the same prices. This plan can help to make products and manufacture products at lower prices than rivalries and the sustainability of the company will be enhanced.
Enhancement in funding prospect of new strategy
Enhancement of funding will help to implement various tools and technologies for better production as well as better management. Besides that, funding enhancement can be considered as beneficial because it can help to motivate employees by providing compensation and incentive according to the performance. It also can assist to improve business prospectus as much as possible. This plan will improve business position and business stability within seven months.
Advantages of implementation plan
An implementation plan can help to understand needed resources as well as needed personnel of TPS. It helps to improve the entire business plan and business strategy of the company along with competitive advantages. On the contrary, implementation plans are closely associated with the improvement of the entire business (Dinis-Carvalho, 2020). It is said that implementing a plan can help to overcome problems as well as improve necessary requirements within a short period of time. Sometimes, the company faces problems to understand the business position including market position. As per the context of this study, a strategic implementation plan can help to improve the sustainability and growth of TPS along with profits and revenues. As opined by Maginnis, Hapuwatte and Jawahir (2017), implementation plans usually will help to improve as well as enhance the entire business strategy of Toyota production system. The goals and objectives of TPS will be improved by all of these implementation plans and the company can achieve its aim very easily by all of these implementation plans. Furthermore, the production and manufacturing process will be improved by all of these.
5. Design process
The design process of Toyota’s production process is based on the philosophy of achieving the entire reduction of waste materials. This renowned TPS system is majorly based on two concepts such as jidoka and just in time concept. The Jidoka concept is based on the automation technology by human touch while the just in time concept refers to continuous process flow. TPS can produce good quality vehicles and other products quickly with the help of these two basic concepts. Therefore, it is said that these two concepts have helped indirectly to satisfy customers as well as to improve profits and revenues of the company (Antunes et al. 2017). Cost reduction approach can be more suitable for this company as it can help improve the competitive advantages of Toyota production system. Improvement of jidoka can help to improve the entire system as well the systems will become safe and reliable with the jidoka concept.
Jidoka mechanism is very beneficial as it can help to improve the production line of the TPS system. As narrated by Carla et al. (2018), human production has severe chances of being misproduction, the Jidoka system can help to improve the mis production as much as possible. This mechanism can make all machinery very easy after one-time use and this can help to enhance production as much as possible. The operating cost will be reduced along with this. Five concepts such as arrangement, tiding, cleanliness, cleaning and training can help to improve the TPS system and the production process will be enhanced (Singh, 2018). Implementation of continuous process flow can help to improve problems of the surface. Various business designs are mentioned in this study that can help to improve the TPS design as much as possible.
- The company has to administer the pull system that can help to prevent overproduction of materials. Besides that, the company has to level the workload that means the work will need to finish with maintaining all patience.
- Creating culture stopping can help to fix all problems and this can help to get right quality products from the initiation.
- The company has to standardize all work of employees that can help to improve employee empowerment as well as the productivity will be enhanced (Tekin et al. 2018).
- Transparent manufacturing, as well as production systems, can help to reduce all problems as issues in production.
- It can be recommended that the company should use reliable and thoroughly tested technology, which can help to improve the production process and the numbers of wastes will be reduced.
- One of the most important and popular designs, the company has to add value in order to provide training to all employees. Providing training to leaders will aid to understand work as well as the process of working will be improved.
- The number of well-experienced will be needed to improve by the company and it helps to improve the profits and revenues of the company as much as possible.
- Moreover, the company has to solve any problems as well as any issues from the root.
Furthermore, more design implementations are described as they can help the production process of TPS (Fireman Saurin&Formoso, 2018).
Introduction of 5s
The 5s concept includes arrangement, tiding, cleanliness, cleaning, and training can help to improve the TPS system and the production process will be enhanced.
Introduction of one-piece production
The 5 concept can allow Toyota to introduce the fundamental requisites and the just-in-time (JIT) concept will be implemented by this. The training of multi-functioned workers will be provided by this concept as well as the layout of machinery processes will be improved by these five concepts.
Administration of small lot size production
It is considered as the second stage and the five concepts can help to improve the setup method in order to reduce the lot size. The production will be improved more as well as the operating cost will be reduced by this (Slim, Rémy&Amadou, 2018).
Establishing productions smoothing
The kanban card system will be introduced in this system in order to improve the production process as well as productivity. The time of workers will be reduced in this stage as well as the machinery will be improved by 5s concepts.
Implementation of kanban system
The kanban system will be implemented in this stage and this system will aid to control Just in time (JIT) production system with the help of operating standardization, smoothing production, reduced setup time, and improvement activities.
All of these can help to improve decision-making as well as increase added value. The elimination of wastes will be reduced. Evidence has suggested that TPS aims to improve profit and revenues by declining costs through reducing wastes. The production process has to adopt the market in order to understand the entire situation as well as the company has to increase the smoothness and flexibility of the production process. The kanban system will be beneficial for TPS and it can help to improve manufacturing through manual work. As mentioned by Urban &Rogowska (2020), the kanban system can be considered as the control of overproduction. The Kanban system is usually two types such as withdrawal kanban and production ordering kanban system. The company can implement kanban technology with the help of the kanban system. TPS workers are very multi-talented and flexible production procedures can help them to improve production more. More productivity is closely related to more growth
Several assumed advantages of the design process
All of these design processes can provide numerous advantages and the production system of TPS will be improved.
- This design process will improve the process of TPS and this TPS system will use several lead methods such as 5S and kanban system that can reduce the work errors of employees. The defects in the production system will be improved by this.
- This design process of TPS will reduce wastes by reducing costs as well as improving efficiencies. The over-production, under-production, unnecessary inventory all are considered as wastes and this will be reduced by this process.
- Improved production is strongly related to customer satisfaction. Therefore, it is said that this designing procedure of TPS can enhance customer satisfaction. In addition, the zero-defect policy of TPS will be improved by this designing process.
- The safety of employees and customers will be improved by this designing process and the 5s concepts will help employees to reduce hazards and conflicts. The risks of driving will be reduced by this designing process (Slim, Rémy&Amadou, 2018).
Kaizen is designed as a tool and this tool can help to improve Toyota production system and it can be more beneficial to reduce wastes. As narrated by Urban &Rogowska (2020), without kaizen, Toyota production system will not have any foundation. The main aim of this tool is to improve efficiency of warehouse workers, purchasing orders, and others. As per this study, this tool can help to improve the warehouse manufacturing process and purchasing orders as much as possible.
6. Conclusion
It can be concluded from the study that Toyota Production System (TPS) is a suitable aspect that in turn can help to develop productivity of an organization. The high growth of organization can be possible with the help of such systems and reliability of data can be acquired. Effective business development can be possible in the case of TPS systems and strategic intervention can be effective to make business reliable. In order to implement a new system, continuous flow of products can be possible and real-time measurement of data can be possible with high efficiency. However, the number of production costs has increased through the TPS system and data validation can also be affected in a strategic manner. Systematic development of the target process can be acquired through selected system and measurement of all challenges can be possible. Moreover, Toyota is able to develop its business view with the help of such advancement and this can help to acquire more profit in any situation.
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