Syllabus

Description of Course

The Toyota Production System (TPS) master’s course (LT-M1) is a continuation of the content learned in the Lean Thinking Advanced Course (LT-A1). This course provides a deep dive into the history and operational aspects of the Toyota Production System and The Toyota Way philosophy.

The course covers the pillars of Jidoka, Just-in-Time (JIT), and the foundational aspects of the Toyota Production System and components. It covers the pillars and elements of the Toyota Way and what it means to apply them.

Duration of Training

The Toyota Production System (LT-M1) master’s course requires 16 hours of training and can be taken as a two-day in-person training session, an online live virtual class, or as an asynchronous self-paced online training using The Flow System’s learning management system (LMS). This course can be taught publicly or privately to any organization.

Participants must complete the training before receiving a code allowing them to take the Toyota Production System (LT-M1) assessment for accreditation. The fee for the assessment is included in the course fee for training attendees.

At the master’s level, participants will demonstrate an ability to apply the new knowledge and complete an online assessment. The master’s level courses’ application portion will be reviewed by peers and industry experts in their chosen field.

Participants who attend the training will have two attempts at the Toyota Production System (LT-M1) assessment. Participants who wish to forgo the training and jump straight to the assessment may do so but must first buy a code and will only have one attempt as opposed to those taking the training. You can buy a code below by clicking ‘Take Assessment.’

Objectives of Course

This course is a master’s course that continues to build on the material learned from both the Foundations (FS-1) and the Lean Thinking Advanced (LT-A1) courses. As a mastery level course, participants will be required to envision applying the material covered in the course to their place of work. After successfully completing this course participants should be able to:

• Explain the pillars of the system.
• Explain the Toyota Way philosophy that underpins TPS.
• Define the foundational goals of TPS.
• Define the desired outcomes of TPS.
• Describe how to use the elements of the Toyota Way:
  • Challenge
  • Kaizen
  • Genchi Genbutsu
  • Respect
  • Teamwork
• Describe how to design and apply Standard Work.
• Explain how to calculate and use Takt Time, Cycle Time, Lead Time.
• Described the elements of PDCA.
• Explain the 4Ms.
• Define the 7 wastes in TPS and at least 2 other identified wastes.
• Define 5S and the differences between 4S and 5S.
• Define and explain continuous flow.
• Differentiate between batch vs pull systems.
• Explain Kanban in a pull system.
• Explain ANDON, Poka Yoke, & Defect Detection.
•  Define Fixed Position Stop and Line Stop.
•  Explain leveled workflow and Heijunka.
•  Explain the basics of Visual Control and how to apply them.