How Toyota’s Thinking People System (TPS) can Improve Efficiency of Textile Industry

M A Mohiemen Tanim May 28, 2023Last Updated: May 28, 2023

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‘Thinking People System’ (TPS) of Toyota Production System(TPS)

The ‘Thinking People System’ (TPS) is a fundamental principle of the Toyota Production System, which emphasizes the active involvement of team members in the decision-making process to ensure the smooth operation of the system. Unlike traditional approaches where employees function like machines, TPS encourages individuals to think critically about the process and make timely decisions to improve its efficiency. This level of involvement instills a sense of responsibility for the process’s success, leading to increased morale and higher quality outcomes.

TPS recognizes the crucial role of kaizen, the concept of continuous improvement, in achieving operational excellence. Rather than relying solely on experts or management for improvement ideas, kaizen involves everyone within the organization. It leverages the extensive knowledge, skills, and experience of the individuals directly involved in the process. This inclusive approach allows for a wide range of perspectives and insights, leading to more effective and sustainable improvements.

To facilitate this collaborative mindset, TPS encourages regular communication and problem-solving discussions. An example of this is the asa-ichi meeting held each morning, where team members gather to address quality deviations and work together to eliminate their root causes. By actively involving employees in problem-solving and decision-making, TPS fosters a culture of continuous improvement and empowers individuals to contribute to the success of the organization.

An impressive illustration of the TPS philosophy in action can be seen at Toyota Material Handling Europe’s production sites. In a typical year, approximately 3,000 improvement proposals are generated by the workforce, showcasing the depth of employee engagement and their commitment to driving positive change. This exemplifies how TPS, with its focus on the thinking and involvement of people at all levels, cultivates a culture of innovation, efficiency, and continuous improvement within an organization.

Implementing the Thinking People System (TPS) in the Textile Industry

Implementing the Thinking People System (TPS) in the textile industry can bring about significant improvements in operational efficiency, quality, and employee engagement. Here are some steps to consider when implementing TPS in the textile industry:

Create a Culture of Continuous Improvement: Foster a culture that encourages employees at all levels to contribute their ideas and participate in problem-solving. Promote the belief that every employee’s input is valuable and that their involvement is crucial to the success of the organization.
Provide Training and Development: Offer training programs to enhance employees’ problem-solving skills, critical thinking, and process understanding. Develop their knowledge of TPS principles and techniques, such as root cause analysis, standardized work, and visual management.
Establish Communication Channels: Implement regular forums for communication, such as team meetings, suggestion systems, and feedback mechanisms. Encourage open dialogue and active participation to exchange ideas and identify improvement opportunities.
Empower Employees: Delegate decision-making authority to employees who are directly involved in the textile production process. Give them the autonomy and responsibility to make timely decisions and take ownership of their work areas.
Implement Visual Management: Utilize visual management tools, such as Kanban boards, performance dashboards, and work instructions, to make processes and performance indicators easily understandable and visible. Visual management enhances transparency, communication, and accountability.
Encourage Cross-Functional Collaboration: Break down departmental silos and promote collaboration across different functions and teams. Encourage employees from various areas, such as production, quality control, and logistics, to work together on improvement projects to gain a holistic view of the processes.
Conduct Regular Kaizen Events: Plan and execute focused improvement events, known as kaizen events, where cross-functional teams collaborate to identify and implement improvements. These events provide an opportunity to tackle specific challenges and drive rapid improvement.
Emphasize Standardized Work: Develop standardized work procedures and document best practices to ensure consistency and eliminate process variations. Standardized work serves as a baseline for continuous improvement efforts and provides a foundation for problem-solving.
Provide Recognition and Rewards: Recognize and reward employees for their contributions to process improvements. Celebrate successes, share best practices, and create a sense of achievement and motivation among the workforce.
Monitor and Evaluate Progress: Establish key performance indicators (KPIs) to measure the impact of TPS implementation. Regularly assess progress, review performance metrics, and provide feedback to ensure continuous improvement efforts are aligned with organizational goals.

By implementing the Thinking People System in the textile industry, organizations can leverage the knowledge and expertise of their employees to drive innovation, improve efficiency, and enhance overall operational performance.