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Mar 13, 2026
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MANF 424 - Toyota Production System
Credits: 5
Variable Credit Course: No
Lecture Hours: 55
Lab Hours: 0
Worksite/Clinical Hours: 0
Other Hours (LIA/Internships): 0
Course Description: Explores lean manufacturing through the Toyota Production System philosophy, emphasizing waste elimination, continuous improvement (Kaizen), and just-in-time practices. Analyze production processes, implement tools such as 5S and Kanban, and foster a quality-focused culture. Projects tie lean methods to practical production scenarios to solidify foundational knowledge.
Prerequisite: Admission to BASAMD program and Dept. Chair permission.
Meets FQE Requirement: No
Integrative Experience Requirement: No
Student Learning Outcomes
- Evaluate production workflows to identify waste and recommend lean improvements using Toyota Production System principles.
- Design process improvements using lean tools such as Kanban and 5S to enhance efficiency and quality in production.
- Integrate continuous improvement methods such as Kaizen and PDCA cycles with quality-at-the-source principles like Jidoka to systematically enhance manufacturing processes.
- Evaluate organizational culture factors affecting lean implementation, and propose strategies to sustain a continuous improvement environment.
Course Contents
- Lean manufacturing philosophy and the Toyota Way principles.
- Seven wastes (Muda) identification and elimination techniques.
- 5S workplace organization and visual management.
- Just-in-Time (JIT) production and Kanban scheduling systems.
- Jidoka (autonomation) and built-in quality at the source.
- Standardized work, takt time, and production leveling (Heijunka).
- Kaizen and Plan-Do-Check-Act (PDCA) continuous improvement cycles.
- Value stream mapping and process flow analysis.
- Quick changeover (SMED) and small-batch production methods.
- Lean performance metrics (quality, cost, delivery) and waste reduction.
- Cultivating lean culture, teamwork, and change management for TPS.
- Application of TPS concepts in project and capstone contexts.
Instructional Units: 5
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