Toyota Production System

By Prof. Rajat Agrawal   |   IIT Roorkee
Learners enrolled: 532
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
Course Status : Upcoming
Course Type : Elective
Duration : 8 weeks
Start Date : 23 Aug 2021
End Date : 15 Oct 2021
Exam Date : 23 Oct 2021
Enrollment Ends : 23 Aug 2021
Category :
  • Management Studies
  • Operations
Credit Points : 2
Level : Undergraduate/Postgraduate

Course layout

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 

Books and references

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

Instructor bio

Prof. Rajat Agrawal

IIT Roorkee
Dr. Rajat Agrawal is a Professor at Department of Management Studies, Indian Institute of Technology Roorkee, Roorkee. He is Associate Dean for Innovation and Incubation, IPR Chair Professor of DPIIT, Govt of India at IIT Roorkee.

He is a Joint faculty member at Center of Excellence for Disaster Mitigation and Management and Associate faculty member at Center of Excellence for Transportation Management, IIT Roorkee. He initiated the process of establishing the Design Innovation Centre at IIT Roorkee and presently Co-PI and Co-coordinator of the Centre. Dr. Rajat was a visiting fellow to Copenhagen Business School, Copenhagen, Denmark. He was awarded ICCR Chair at Indonesia in year 2016-17. His area of interest is Production and Operations Management including Supply Chain Management, Manufacturing Strategy and World Class Manufacturing.

He has guided 19 Ph D thesis in these areas and currently 12 students are working under his guidance. He has completed 12 research/consultancy projects of National and
International importance. Three projects worth over Rs2.5 Cr are in progress.

He has more than 120 research papers in refereed journals and more than 25 research papers in refereed conference proceedings. He has authored one book published by Bloomsbury and book chapters in 8 books. He organized First PANIIT International Management Conference in year 2018.

Course certificate

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: 23 October 2021 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

YOU WILL BE ELIGIBLE FOR A CERTIFICATE ONLY IF AVERAGE ASSIGNMENT SCORE >=10/25 AND EXAM SCORE >= 30/75. 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 will not be dispatched.

Once again, thanks for your interest in our online courses and certification. Happy learning.

- NPTEL team

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