Book: Toyota Production System, Fourth Edition

New material on e-kanban, kaizen costing, and one-piece production in practice

Published: Friday, October 14, 2011 - 08:58

(CRC Press: Boca Raton, FL) -- A bestseller for almost three decades, Toyota Production System: An Integrated Approach to Just-In-Time, Fourth Edition, by Yasuhiro Monden (CRC Press, 2011), supplies in-depth coverage of Toyota’s production practices, including theoretical underpinnings and methods for implementation. Exploring the latest developments in the Toyota Production System (TPS) framework at Toyota, this new edition updates the classic with new material on e-kanban, mini-profit centers, computer-based information systems, and innovative solutions to common obstacles in TPS implementation.

Yasuhiro Monden, instrumental in introducing the just-in-time (JIT) production system to the United States, explains the logic and methodologies of the TPS. Extending the humanized aspect of production introduced in the third edition, Toyota Production System: An Integrated Approach to Just-In-Time, Fourth Edition explains how to cultivate the culture and way of thinking needed to establish the TPS holistically across your organization. Exploring the link between kaizen methods and calculation methods in TPS, this edition includes new chapters on:

• The goal of TPS
• One-piece production in practice
• Kaizen costing
• Material handling in an assembly plant
• Smoothing kanban collection
• Determination of the number of kanban
• New developments in e-kanban
• Cultivating the spontaneous kaizen mind

Following in the footsteps of its bestselling predecessors, the fourth edition provides easy-to-follow guidance for implementing the TPS in your organization. It explains how Toyota has adapted and reacted to recent fluctuations in demand, quality problems, and recalls. It also includes an appendix that considers the recent tsunami in Japan and investigates how to reinforce the JIT system to ensure supply-chain flow during sudden stoppages at individual locations within the chain.

Chapter titles

• Total Framework of the Toyota Production System
• Implementation Steps for the Toyota Production System
• Adaptable Kanban System Maintains Just-in-Time Production
• Supplier Kanban and the Sequence Schedule Used by Suppliers
• Smoothed Production Helps Toyota Adapt to Demand Changes and Reduce Inventory
• The Information System for Supply-Chain Management between Toyota, Its Dealers, and Parts Manufacturers
• How Toyota Shortened Production Lead Time
• Machine Layout, Multifunctional Workers, and Job Rotation Help Realize Flexible Workshops
• One-Piece Production in Practice
• Standard Operations Can Attain Balanced
• Reduction of Setup Time—Concepts and Techniques
• 5S—Foundation for Improvements
• Autonomous Defect Control Ensures Product Quality
• Cross-functional Management to Promote Companywide Quality Assurance and Cost Management
Kaizen Costing
• Material Handling in an Assembly Plant
• Further Practical Study of the Kanban System
• Smoothing Kanban Collection
• Applying the Toyota Production System Overseas
• Sequencing Method for the Mixed-Model Assembly Line to Realize Smoothed Production

About the author

Yasuhiro Monden is professor emeritus at the University of Tsukuba, Japan. He currently serves as visiting professor in the graduate program of the Nagoya University of Commerce and Business. He received his Ph.D. in management science and engineering from the University of Tsukuba.

Monden has gained valuable practical knowledge and experience from his research and related activities in the Japanese automobile industry. He was instrumental in introducing the JIT production system to the United States. However, his research fields are wide, covering not only production and operations management but also managerial and financial accounting, corporate finance, and business economics. 

 Monden’s international activities have included visiting professorships at the State University of New York at Buffalo (1980–81), California State University in Los Angeles (1991–92), and Stockholm School of Economics in Sweden (1996). He was also regional director of the Production and Operations Management Society (POMS), and has acted as international director of the Management Accounting Section of the American Accounting Association (AAA).

This book is also available as an e-textbook.

About The Author

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