Toyota Production System

By Dr Rajat Agrawal   |   IIT Roorkee
Manufacturing is one of the important activity for wealth generation. Countries like China, Thailand, Vietnam etc are creating an enabling environment for developing these nations as major industrial ones. Therefore, there is an increasing interest in manufacturing activities. Toyota car company at Japan is a very interesting case study to learn many things to make manufacturing competitive. Toyota consistently raises the bar for manufacturing, product development, and process excellence. The result is an amazing business success story: steadily taking market share from price cutting competitors, earning far more profit than any other automaker, and winning the praise of business leaders worldwide.  
The proposed course will discuss various aspects of Toyota’s approach and will also focus to achieve sustainability through excellence in operations

INTENDED AUDIENCE:  (1) Industry people who wants to use “operations” for competitive advantage. 
                                         (2) Students doing research in operations management. 
                                         (3) Students doing Masters and Bachelors degrees in area of operations management, industrial engineering etc.
                                         (4) Professionals who are interested in knowing the best practices in operations.   

PREREQUISITES:           Production and Operations Management         

INDUSTRY SUPPORT:    This course will be highly useful for manufacturing organizations. Particularly companies such as Hero,
                                          Maruti, BHEL, Rockman, Bajaj, Tata etc. will find this course valuable

Learners enrolled: 2965


Course Status : Completed
Course Type : Elective
Duration : 8 weeks
Start Date : 26 Aug 2019
End Date : 18 Oct 2019
Exam Date : 16 Nov 2019
Category :
  • Management Studies
  • Level : Undergraduate
    This is an AICTE approved FDP course


    Week 1: (1)  Manufacturing Excellence
    (2)  Global Environment
    (3)  Production System
    (4)  Operations Strategy 
    (5)  The Heart of the TPS: Eliminating Waste  

    Week 2: (1)  Principles of Toyota Way
    (2)  Culture Behind Toyota Way
    (3)  Toyota Way in Action 
    (4)  Long Term Philosophy 
    (5)  Create Continuous Flow 

    Week 3: (1)  Pull System 
    (2)  Leveling Workload 
    (3)  Get Quality Right the first time 
    (4)  Standardization of Task 
    (5)  Use of Visual Control
    Week 4: (1)  Use of Reliable Technology 
    (2)  Role of Leaders in Manufacturing Philosophy
    (3)  Developing Exceptional Teams  
    (4)  Challenge & Respect Extended Networks   
    (5)  See yourself to understand the situation 
    Week 5: (1)  Developing decisions with Consensus 
    (2)  Becoming Learning Organization   
    (3)  Becoming a Learning Organization: Continuous Improvement
    (4)  Using Toyota Way for other Organization(Service & Technical) 
    (5)  Lean Manufacturing

    Week 6: (1)  Lean Vs Agile Manufacturing
    (2)  Sustainable Manufacturing-I   
    (3)  Sustainable Manufacturing-II   
    (4)  Flexible Manufacturing System 
    (5)  Benchmarking 
    Week 7: (1)   Cultural Issues in Lean 
    (2)   Overview of Lean implementation
    (3)   Significance of Lead time 
    (4)   Techniques to reduce LT 
    (5)   Value Stream Mapping 

    Week 8: (1)   KANBAN Approach 
    (2)   KANBAN Calculation-I
    (3)   KANBAN Calculation-II
    (4)   Theory of Constraints
    (5)   Different Business Excellence Models 


    (1) The Toyota Way , Jeffrey K. Liker , Tata McGraw Hill
    (2) How to implement lean manufacturing, Lonnie Wilson, McGraw Hill


    Prof. Rajat Agrawal is a member of faculty (Associate Professor) at Department of Management Studies, Indian Institute of Technology Roorkee, Roorkee. He is also associate faculty member at Center of Excellence for Disaster Mitigation and Management and Center of Excellence for Transportation Management, IIT Roorkee. He administers various initiatives of IIT Roorkee in the field of IPR, incubation and entrepreneurship in different capacities. He initiated incubation centre at IIT Roorkee.  He is cocordinator of Design innovation centre at IIT Roorkee. He is also IPR Chair Coordinator at IIT Roorkee. Dr. Rajat is a visiting fellow to Copenhagen Business School, Copenhagen, Denmark. His area of interest is Production and Operations Management including Supply Chain Management, Manufacturing Strategy and World Class Manufacturing. He has guided fourteen Ph D thesis in these areas and published papers in journals of Emerald, Sage, Springer, Taylor and Francis, Elsevier, and Inderscience. Currently, ten students are working under him for Ph D thesis.  He has more than 90 research papers in refereed journals and more than 25 research papers in refereed conference proceedings. He has developed more than 20 case studies on various aspects of supply chain management, organisational development, natural resource management, social entrepreneurship, and value co-creation. He has developed more than 15 programmes for All India Radio on various subjects of rural development and technical, management education. He has completed 10 research and consultancy projects. He was also involved in some of the international projects funded by Danish Innovation Council and European Union. He has more than 200 hours of corporate training experience with organisations like BHEL, THDC India Ltd., Power Finance Corporation Ltd., Syndicate Bank, Everest Industries, and Rockman Industries etc. He is reviewer of various national/ international journals. He is a member of Academy of Management, USA ; All India Management Association, New Delhi and ISOL, New Delhi.He has contributed chapters in seven different books published by IGNOU, Delhi, NIOS, Delhi, IGI Global, and Springer. He has co-authored a book titled “Masters Speak: Management Education in India” published by Bloomsbury India Publications.He received Best Teacher Dainik Bhaskar National Education Leadership Awards-2013. He received Noel Deere Gold Medal for paper in management stream in 71st and 72nd annual convention of STAI, consecutively. One of his paper was considered one of the best articles of the Year 2014 by Business Standard. He was also awarded ISOL Research Award 2015 at 5th International conference at Chicago USA. He was also awarded ICCR chair professorship at Indonesia


    • The course is free to enroll and learn from. But if you want a certificate, you have to register and write the proctored exam conducted by us in person at any of the designated exam centres.
    • The exam is optional for a fee of Rs 1000/- (Rupees one thousand only).
    • Date and Time of Exams: 16 November 2019, Morning session 9am to 12 noon; Afternoon Session 2pm to 5pm.
    • Registration url: Announcements will be made when the registration form is open for registrations.
    • The online registration form has to be filled and the certification exam fee needs to be paid. More details will be made available when the exam registration form is published. If there are any changes, it will be mentioned then.
    • Please check the form for more details on the cities where the exams will be held, the conditions you agree to when you fill the form etc.

    • Average assignment score = 25% of average of best 6 assignments out of the total 8 assignments given in the course. 
    • Exam score = 75% of the proctored certification exam score out of 100
    • Final score = Average assignment score + Exam score

    • If one of the 2 criteria is not met, you will not get the certificate even if the Final score >= 40/100.
    • Certificate will have your name, photograph and the score in the final exam with the breakup.It will have the logos of NPTEL and IIT Roorkee. It will be e-verifiable at nptel.ac.in/noc.
    • Only the e-certificate will be made available. Hard copies are being discontinued from July 2019 semester and will not be dispatched