Toyota: Production System, Safety Analysis and Future Directions

Kakuro Amasaka
Aoyama Gakuin University, Tokyo, Japan

Series: Manufacturing Technology Research
BISAC: TEC020000

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Toyota: Production System, Safety Analysis, and Future Directions explains the production methods and future trajectories for the Japanese car company through the strategic development of Toyota’s automobile manufacturing both in Japan and overseas as follows:
Part I gives an overview of the book based on the Toyota Production System (TPS), its advanced production management principles and its aim to create the ¡°simultaneous realization of quality and productivity via process control and process improvement, with priority given to the customer.

In Chapter One, the author describes the outline of the characteristic, aim, and validity” of this book. Chapter Two focuses on the progress and fundamentals of TPS in terms of the just in time (JIT) principle and automobile manufacturing technology, which has contributed to the simultaneous achievement of QCD at Toyota. In Chapter Three, the author asserts the necessity for the evolution of manufacturing in order to deal with the management issues currently facing Japanese manufacturers. Therefore, in this chapter, the author establishes an advanced TPS and its effectiveness of strategic development, surpassing JIT. In Chapter Four, the author develops an advanced TPS for an automobile manufacturing strategy to expand this strategy throughout Japan and overseas.

Safety Analysis to Strengthen Toyota Automobile Manufacturing is the topic of Part II. Today’s management challenge is to provide excellent QCD products ahead of competitors through ¡°market creating¡± activities. In the implementation stage, strategic QCD studies are needed to strengthen core technologies, and to have them mutually linked as a whole. Therefore, the author develops the safety analysis utilizing a statistical science known as the Science of SQC: The New Quality Control Principle for the strengthening of the business and manufacturing processes.

Chapters Five ¨C Seven discuss and demonstrate the effectiveness of the following as the driving force in developing advanced TPS: ¡°Realizing high quality manufacturing, strengthening new manufacturing management technology, and creating an SCM strategy for developing QCD studies of Japan and overseas.

In Part III, the author discusses and demonstrates the future directions for Toyota’s manufacturing strategy. Focusing on a concrete target, the author reconsiders new management tasks foreseen for the advanced manufacturing companies, shifting to expanding global production. Based on the focus of Parts I and II, the author asserts the profitability (justification and validity) for re-progress in automobile manufacturing in order to deal with the management issues currently facing Japanese manufacturers.

In Chapter Eight, as an oversea production strategy, the author propagates an “expanding new integrated production model” to developing countries and discusses the necessity for the global deployment. In Chapter Nine, the author shows and demonstrates the effectiveness of new production progress for re-strengthening global production. In Chapter Ten, the author provides an overall conclusion of the topics covered in this book. (Imprint: Nova)

Preface

Aims and Structure

Overview

Author

Contributing Authors

Acknowledgements

PART I: Toyota Production System

Chapter 1. Introduction

Chapter 2. Toyota Production System (TPS): Basic of JIT

Chapter 3. Advanced Toyota Production System (Advanced TPS): Surpassing JIT

Chapter 4. Developing Advanced TPS for Automobile Manufacturing Strategy

PART II: Safety Analysis to Strengthen Toyota Automobile Manufacturing

Chapter 5. Realizing High Quality Manufacturing

Chapter 6. Strengthening of New Manufacturing Management Technology

Chapter 7. SCM Strategy for Developing QCD Studies of Japan and Overseas

PART III: Future Directions of Toyota Manufacturing Strategy

Chapter 8. Expanding New Integrated Production Model

Chapter 9. Newest Production Progress for Re-strengthening Global Manufacturing

Chapter 10. Conclusion

Index

Chapter 1

Amasaka, K. 1988. (Plenary lecture) Concept and progress of Toyota Production System, Co-sponsorship: The Japan Society of Precision Engineering, The Japan Society for Technology of Plasticity, The Japan Society for Design & Drafting and Hachinohe Regional Advance Technology Promotion Center Foundation, Hachinohe, Aomori-ken, Japan. (in Japanese)
Amasaka, K. 1999a. A study on Science SQC by utilizing Management SQC, A demonstrative study on a new SQC concept and procedure in the manufacturing industry, International Journal of Production Economics, Vol.60-61, pp.591-598.
Amasaka, K. 1999b. The TQM responsibilities for industrial management in Japan - The research of actual TQM activities for business management, The Japanese Society for Production Management, The 10st annual technical conference, Kyushu- Sangyo University, Fukuoka, Japan, pp. 48-54.
Amasaka, K. 2002. New JIT, A New Management Technology Principle at Toyota, International Journal of Production Economics, Vol.80, pp.135-144.
Amasaka, K. 2004a, (Keynote lecture) The past, present, future of production management, The Japan Society for Production Management, The 20th Annual Technical Conference, Nagoya Technical College, Aichi, Japan, pp. 1-8.
Amasaka, K. 2004b. Establishment of performance measurement toward strategic quality management: Key to successful implementation of new management principle, Science TQM, Proceedings of the fourth International Conference on Theory and Practice in Performance Measurement, The Edinburgh International Conference Centre, UK, pp. 515-522.
Amasaka, K. 2004c. Establishment of Strategic Quality Management—Performance Measurement Model - Key to successful implementation of Science TQM (Part 6) -, The Japan Society for Production Management, The 20th Annual Technical Conference, Nagoya Technical College, Japan, pp. 95-98. (in Japanese)
Amasaka, K. 2007a. High Linkage Model “Advanced TDS, TPS & TMS”–Strategic development of “New JIT” at Toyota–, International Journal of Operations and Quantitative Management, Vol. 13, No. 3, pp. 101-121.
Amasaka, K. 2007b. New Japan Production Model, an advanced production management principle: Key to strategic implementation of New JIT, The International Business and Economics Research Journal, Vol. 6, No. 7, pp. 67-79.
Amasaka, K. 2007c. Applying New JIT – Toyota’s global production strategy: Epoch-making innovation of the work environment, Robotics and Computer- Integrated Manufacturing, Vol. 23, Issue 3, pp. 285-293.
Amasaka, K. 2008. Strategic QCD studies with affiliated and non-affiliated suppliers utilizing New JIT, Encyclopedia of Networked and Virtual Organizations, Vol. III, PU-Z, pp. 1516-1527.
Amasaka, K. 2010a. Evolution of TPS fundamentals utilizing New JIT strategy Proposal and validity of Advanced TPS at Toyota, Journal of Advanced Manufacturing Systems, Vol. 9, Issue. 2, pp. 85-99.
Amasaka, K. 2010b. (Keynote lecture) New Manufacturing Principle surpassing JIT towards the 21st century manufacturing, Japanese Operations Management and Strategy Association, The 2nd Annual Conference, Kobe University, Japan. (in Japanese)
Amasaka, K. 2013. The development of a Total Quality Management System for transforming technology into effective management strategy, The International Journal of Management, Vol. 30, No 2, pp. 610-630.
Amasaka, K. 2014, New JIT, New Management Technology Principle: Surpassing JIT, Journal of Procedia Technology special issues, Vol.16, pp. 1135-1145.
Amasaka, K. 2017. Strategic Stratified Task Team Model for realizing simultaneous QCD fulfilment: Two case studies, Journal of Japanese Operations Management and Strategy, Vol. 7, No. 1, pp. 14-35.
Amasaka, K., Kurosu, S., and Morita, M. 2008. New Manufacturing Principle: Surpassing JIT - Evolution of Just in Time, Morikita-shuppan. (in Japanese)
Amasaka, K. and Sakai, H. 2011. The New Japan Global Production Model “NJ-GPM”: Strategic development of Advanced TPS, The Journal of Japanese Operations Management and Strategy, Vol. 2, No. 1, pp. 1-15.
Asahi Shinbun, The manufacturing industry–Skill tradition feels uneasy (May 3, 2005).
Doos, D., Womack, J. P. and Jones, D. T. 1991. The machine that change the world – The story of lean production, Rawson/Harper Perennial, New York.
Ebioka, K., Sakai, H., Yamaji, M. and Amasaka, K. 2007. A New Global Partnering Production Model “NGP-PM” utilizing Advanced TPS, Journal of Business & Economics Research, Vol. 5, No. 9, pp. 1-8.
Goto, T. 1999. Forgotten management origin- Management quality taught by GHQ, Seisansei-shuppan, Tokyo.
Iida, T., Mihara, R. and Amasaka, K. 2013, Constructing Business Process Network System “A-BPNS-NPD,” Journal of Business Case Studies, Vol. 9 No. 4、pp. 343-352.
Ishikawa, A., Morita, Y. and Amasaka, K. 2011, Constructing measures of CS effectiveness to boost subjective quality at manufacturers, International Business & Economics Research Journal, Vol. 10, No. 11, pp. 55-62.
Miyashita, S. and Amasaka, K. 2014. Proposal of a New Vietnam Production Model, NVPM, A new integrated production system of Japan and Vietnam, IOSR Journal of Business and Management, Vol. 16, Issue 12, pp. 18-25.
Nihon Keizai Shinbun. (1) Corporate survey (68QCS)–Strict assessment of TQM (July 15, 1999), (2) Worst record: 40% increase of vehicle recalls (July 6, 2000), (3) Risky “Quality”: Apart from production increase, it is recall rapid increase (February 8, 2006).
Ohno, T. 1977. Toyota Production System, Diamond-sha, Tokyo. (in Japanese)
Okihara, D., Takada, S. and Amasaka, K. 2014. Constructing a model for selecting improvement actions to gain mutual trust between logistics providers and shippers, Journal of Japanese Operations Management and Strategy, Vol. 5, No.1, pp. 74-85.
Sakai, H. and Amasaka, K. 2008. Human-Integrated Assist System for intelligence operators, Encyclopedia of Networked and Virtual Organization, Vol. II, G-Pr, pp. 678-687.
Sakai, H. and Amasaka, K. 2012. Creating a Business Process Monitoring System “A-IOMS” for software development, Academic Journal of Chinese Business Review, Vol. 11, No. 6, pp. 588-595.
Sakai, H. and Amasaka, K. 2014. How to build a linkage between High Quality Assurance Production System and Production Support Automated System, Journal of Japanese Operations Management and Strategy, Vol. 4, No.2, pp. 20-30.
Siang, Y. Y., Sakalsiz, M. M. and Amasaka, K. 2010. Proposal of New Turkish Production System “NTPS,” Integration and evolution of Japanese and Turkish production system, Journal of Business Case Study, Vol. 6, No. 6, pp. 69-76.
Taylor, D. and Brunt, D. 2001. Manufacturing operations and supply chain management–The lean approach–, First edition published by Thomson Leaning, London.
Toyota Motor Corporation. 1987. The Toyota Production System and a glossary of special teams used at production Job-sites at Toyota.
Uchida, K., Tsunoi, M. and Amasaka, K. 2012, Creating Working Value Evaluation Model “WVEM,” International Journal of Management & Information Systems, Vol. 16, No. 4, pp. 299-306.
Yamaji, M. and Amasaka, K. 2007a. New Japan Quality Management Model: Implementation of New JIT for strategic management technology, The International Business & Economics Research Journal, Vol. 7, No. 3, pp. 107-114.
Yamaji, M. and Amasaka, K. 2007b. Proposal and validity of Global Intelligence Partnering Model for corporate strategy, GIPM-CS, Advances in Production Management Systems, Springer, pp. 59-67.
Yamaji, M., Sakatoku, T. and Amasaka, K. 2008, Partnering Performance Measurement “PPM-AS” to strengthen corporate management of Japanese automobile assembly makers and suppliers, International Journal of Electronic Business Management, Vol. 6, No. 3, pp. 139-145.
Womack, J. P. and Jones, D. 1994. From lean production to the lean enterprise, Harvard Business Review, March-April, pp. 93-103, New York.

Chapter 2

Amasaka, K 2007. Developing the high-cycled quality management system utilizing New JIT, in Proceedings of the Seventh International Conference on Reliability and Safety, Beijing, China, pp. 248-253.
Amasaka, K. (Ed.). 2003. The origin of manufacturing: Progress of the intelligence quality control chart: Digital engineering and high quality assurance, Japanese Standards Association, Tokyo. (in Japanese)
Amasaka, K. 1984a. Process control of the bolt tightening torque of automotive chassis parts (Part 1), Standardization and Quality Control, Vol. 37, No. 9, pp. 97-104. (in Japanese)
Amasaka, K. 1984b. Process control of the bolt tightening torque of automotive chassis parts (Part 2), Standardization and Quality Control, Vol. 37, No. 10, pp. 71-76. (in Japanese)
Amasaka, K. 1985. Management of the quenching process of the automotive chassis parts in case measurement takes time, Standardization and Quality Control, Vol. 38, No. 3, pp. 93-100. (in Japanese)
Amasaka, K. 1986. The improvement of the corrosion resistance for the front and rear axle unit of the vehicle - QCD research activities by plant production engineers, The Japanese Society for Quality Control, The 30th Technical Conference, Nagoya, Aichi, Japan, pp. 20-25.
Amasaka, K. 1988. (Plenary lecture) Concept and progress of Toyota Production System, Co-sponsorship: The Japan Society of Precision Engineering, The Japan Society for Technology of Plasticity, The Japan Society for Design and Drafting and Hachinohe Regional Advance Rechnology Promotion Center Foundation, Hachnohe, Aomori-ken, Japan. (in Japanese)
Amasaka, K. 1988. Electrodes of Arc welding, Surface modification technology- A dry process and its application, The Japan Society forPrecision Engineering, Editing of surveillance study subcommittee about surface modification, Nikkan Kogyo Sinbun, Ltd., pp.304-311. (in Japanese)
Amasaka, K. 1989. TQC at Toyota: Actual state of quality control activities in Japan (Special lecture), in The 19th Quality Control Study Team for Europe, Union of Japanese and Engineers, Statistical Quality Control, Vol. 39, pp. 107-112.
Amasaka, K. 1999. A study on Science SQC by utilizing Management SQC, A demonstrative study on a new SQC concept and procedure in The Manufacturing Industry, International Journal of Production Economics, Vol. 60-61, pp. 591-598.
Amasaka, K. 1999. New QC circle activities at Toyota, A training of trainer’s course on evidence-Based on participatory quality improvement (Special lecture), The International Health Program (TOT Course on EPQI), pp. 1-7, Touhoku University School of Medicine (WHO Collaboration Center), Sendai-city, Miyagi, Japan.
Amasaka, K. 1999. The TQM responsibilities for industrial management in Japan - The research of actual TQM activities for business management, The Japanese Society for Production Management, The 10st Annual Technical Conference, Kyushu- Sangyo, University, Fukuoka, Japan, pp. 48-54. (in Japanese)
Amasaka, K. 2000. Basic thought of JIT – Concept and progress of Toyota Production System (Plenary lecture), The Operations Research Society of Japan, Strategic research group-1, Tokyo. (in Japanese)
Amasaka, K. 2000. New JIT, A New Principle for Management Technology 21C:Proposal and Demonstration of TQM-S in Toyot(Special Lecture), Proceedings of The 1st World Conference on Production and Operations Management, Sevilla, Spain, pp. 15-27.
Amasaka, K. 2000. Partnering chains as the platform for Quality Management in Toyota, Proceedings. of the 1st World Conference on Production and Operations Management, Seville, Spain, pp. 1-13 (CD-ROM).
Amasaka, K. 2002, Intelligence production and partnering for realizing high quality assurance (Invited lecture), The 94th of Japan Society of Mechanical Engineers Tokai branch, Nagoya, Aichi, Japan, pp. 35-42. (in Japanese)
Amasaka, K. 2002. New JIT, a new management technology principle at Totota, International Journal of Production Economics, Vol. 80, pp. 135-144.
Amasaka, K. 2002b. (Plenary Lecture) Intelligence production and partnering for embodying a high quality assurance, The Japan Society of Mechanical Engineers, The 94th Course of JSME Tokai Branch, Nagoya, Japan, pp. 35-42.
Amasaka, K. 2003. New application of strategic quality management and SCM, Proceedings of Group Technology / Cellular Manufacturing World Symposium, Columbus, Ohio, pp. 265-270.
Amasaka, K. 2003. Proposal and implementation of the “Science SQC” Quality Control Principle, International Journal of Mathematical and Computer Modeling, Vol. 38, No. 11-13, pp. 1125-1136.
Amasaka, K. 2004a. Development of “Science TQM”, A new principle of quality management: Effectiveness of strategic stratified task team at Toyota, International Journal of Production Research, Vol. 42, No. 17, pp. 3691-3706.
Amasaka, K. 2004a. The past, present, future of production management (Keynote lecture), The Japan Society for Production Management, The 20th Annual Technical Conference, Nagoya Technical College, Aichi, Japan, pp. 1-8.
Amasaka, K. 2004b. Development of “Science TQM”, a new principle of quality management: Effectiveness of Strategic Stratified Task Team at Toyota, International Journal of Production Research, Vol. 42, No. 17, pp. 3691-3706.
Amasaka, K. 2004b. The past, present, future of production management (Keynote lecture), The Japan Society for Production Management, The 20th Annual Technical Conference, Nagoya Technical College, Aichi, Japan, pp. 1-8.
Amasaka, K. 2004c. Development of “Science TQM”, A new principle of quality management: Effectiveness of strategic stratified task team at Toyota, International Journal of Production Research, Vol. 42, No. 17, pp. 3691-3706.
Amasaka, K. 2004c. Science SQC, New Quality Control Principle: The quality strategy of Toyota, Springer-Verlag Tokyo.
Amasaka, K. 2006. Evolution of TPS fundamentals utilizing New JIT strategy: Toyota’s simultaneous realization of QCD fulfillment models, Proceedings of the International Manufacturing Leaders Forum, Taipei, Taiwan, pp. 1-6.
Amasaka, K. 2007. (Special lecture)The forefront of manufacturing technology: Evolution of Toyota Production System - The quality technological strategy by Science TQM, The Small and Medium Enterprise Agency, Ministry of Economy, Trade and Industry, “The small and medium enterprises - Personnel training task utilizing the technical college etc. in the Heisei 19 fiscal year,” Hachinohe intelligent plaza / Hachinohe Regional Advance Technology Prompotion Center Foundation, Hachinohe, Aomori, Japan. (in Japanese)
Amasaka, K. 2007. High linkage model “Advanced TDS, TPS & TMS”-Strategic development of “New JIT” at Toyota, International Journal of Operations and Quantitative Management, Vol. 13, No. 3, pp. 101-121.
Amasaka, K. 2008. Strategic QCD studies with affiliated and non-affiliated suppliers utilizing New JIT, Encyclopedia of Networked and Virtual Organizations, Vol. III, PU-Z, pp. 1516 -1527.
Amasaka, K. 2008b. Science TQM, a new quality management principle: The quality management strategy of Toyota, The Journal of Management & Engineering Integration, Vol. 1, No. 1, pp. 7-22.
Amasaka, K. 2009, The Foundation for advancing the Toyota Production System utilizing New JIT, Journal of Advanced Manufacturing Systems, Vol. 80, No. 1, pp. 5-26.
Amasaka, K. 2009. (Invitation lecture) New JIT, advanced management technology principle: The global management strategy of Toyota, International Conference on Intelligent Manufacturing and Logistics System, and Sympojium on Group Technology and Cellular Manufacturing, Kiitakyushu, Japan, pp. 1-16.
Amasaka, K. 2009a. The Foundation for Advancing the Toyota Production System utilizing New JIT, Journal of Advanced Manufacturing Systems, Vol. 80, No. 1, pp.5-26.
Amasaka, K. 2009b. An Intellectual Development Production Hyper-cycle Model - New JIT fundamentals and applications in Toyota-, International Journal of Collaborative Enterprise, Vol. 1, No. 1, pp. 103-127.
Amasaka, K. 2014. New JIT, New Management Technology Principle, Taylor & Francis, Danvers, MA / CRC Press, Boca Raton, FL.
Amasaka, K. and Ishida, T. 1991. Tempered equipment, Aichi Invention Encouragement Prize, Aichi Japan Institute of Invention and Innovation, Aichi-ke, Japan.
Amasaka, K. and Kamio, M. 1985. Process improvement and process control: The example of axle-unit parts of the automobile, Union of Japanese and Engineers, Statistical Quality Control, Vol. 36, No. 6, pp. 38-47. (in Japanese)
Amasaka, K. and Kamio, M. 1985. Process improvement and process control: An example of the automotive chassis patrs process, Quality Control. Union Japanese Scientist and Engineers, Vol. 36, No. 6, pp. 38-47. (in Japanese)
Amasaka, K. and Saito, H. 1983. Mechanization of an sensory inspection - An example of viewing of a damping force–”Lissajous curve” of the front shock absorber, Central Japan Quality Control Association, Annual Quality Control Conference 1983, Nagoya, Aichi, Japan, pp. 48-54. (in Japanese)
Amasaka, K. and Sakai, H. 2010. Evolution of TPS fundamentals utilizing New JIT strategy: Proposal and validity of Advanced TPS at Toyota, Journal of Advanced Manufacturing Systems, Vol. 9, Issue 2, pp. 85-99.
Amasaka, K. and Sugawara, K. 1988. Q.C.D research activities of the engineer of the manufacture site: Improvement of paint corrosion resistance of shock absorber parts, Quality Control, Union Japanese Scientist and Engineers, Vol. 39, No. 11, pp. 337-344. (in Japanese)
Amasaka, K. and Yamada, K. 1991. Re-evaluation of the present QC concept and methodology in auto-industry: Development of SQC renaissance at Toyota, Quality Control, Vol. 42, No. 4, pp. 13-22.
Amasaka, K. and Yasuda, K. 1998. The coloring method of a welding bead, Japanese Patent No. 2558493. (in Japanese)
Amasaka, K. Ed. 2013. Science TQM, New Quality Management Principle, The quality management strategy at Toyota, Bentham Science Publishers, Sharjah, U.A.E / Oak Park, IL / AG Bussum, The Netherlands.
Amasaka, K., Iwata, M. Fujii, M. 1988a. Development and the effect of the welding nozzle made from all ceramics, Engineering Materials, Nikkan Kogyo Sinbun. Ltd., Vol. 36, No. 10, pp. 60-64. (in Japanese)
Amasaka, K., Kurosu, S. and Morita, M. 2008. New Manufacturing Principle: Surpassing JIT - Evolution of fJust in Time, Morikita-shuppan, Tokyo. (in Japanese)
Amasaka, K., Kurosu, S., and Morita, M. 2008. New Theory of Manufacturing- Exceed JIT: Evolution of Just-in-Time, Morikita-Shuppan, Tokyo. (in Japanese)
Amasaka, K., Mitani, Y. and Tsukamoto, H. 1993. Research into rust prevention quality assurance for plated components using SQC: Improvement of surface smoothness of rod pistons ground by centerless gringing machine, Quality, Japanese Society for Quality Control, Vol. 23, No. 2, pp. 90-98. (in Japanese)
Amasaka, K., Ohmi, H. and Murai, H. 1990. The improvement of the corrosion resistance for axle unit of the vehicle, Coatings Technology, Vol. 25, No. 6, pp. 230-240.
Amasaka, K., Okumura, Y. and Tamura, N. 1988b. Improvement of paint quality for automotive chassis parts, Standardization and Quality Control, Vol.

41, No. 2, pp. 53-62. (in Japanese)
Amasaka, K., Tsukada, H. and Ishida, M. 1982. Development of the tempering machine using mid-frequency of the rear axle shaft, The Energy Conservation Center, Annual Technical Conference 1982, Nagoya, Aichi, Japan, pp. 193-201.
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Hamel, G. and Prahalad, C.K. (1994). Competing for the future, Harvard Business School Press, Boston.
Hayashi, N. and Amasaka, K. 1990. Concept and progress of Toyota Production System: The physical distribution improvement in manufacture (Special lecture), The Annual Conference of Japan Physical Distribution Management Association, Vol. 3, pp.4-2-1~4-2-12, Tokyo. (in Japanese)
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Nihon Keizai Shinbun. Corporate Survey (68QCS): Strict Assessment TAM – Development of Easy-use Techniques (July 15, 1999) / Worst Record 40% Increase of Vehicle Recalls (July 6, 2000) / IT Innovation of Manufacturing (January 1, 2001) / The Vehicle Quality Survey I US – 1. Toyota, 2. Honda, 3. GM (May 31, 2002) / Risky “Quality”: Apart from Production Increase, it is Recall Rapid Increase (February 8, 2006). (in Japanese)
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Ohno. T. 1977. Toyota Production System, Diamond-sha, Tokyo. (in Japanese)
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Roos, D., Jones, D. T. and Womack. J. P. 1991. The Machine that Change the World – The Story of Lean Production, Rawson / Harper Perennial, New York.
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Taylor, D. and Brunt, D. 2001. Manufacturing operations and supply chain management - The Lean Approach, Thomson Leaning, London.Amasaka, K. 1988. (Plenary lecture) Concept and progress of Toyota Production System, Co-sponsorship: The Japan Society of Precision Engineering, The Japan Society for Technology of Plasticity, The Japan Society for Design and Drafting and Hachinohe Regional Advance Rechnology Promotion Center Foundation, Hachnohe, Aomori-ken, Japan. (in Japanese)
Toyota Motor Corporation. 1987. The Toyota Production System and A Glossary of Special Terms Used at Production Job-sites at Toyota.
Toyota Motor Corporation. 1997. Creation is infinite: The history of the Toyota Motor Corporation 50 year. (in Japanese)
Womack, J. P. and D. Jones. 1994. From Lean Production to the Lean Enterprise, Harvard Business Review, March-April, pp. 93-103, New York.
Womack, J. P. and Jones, D. T. 1994. From lean production to the lean enterprise, Harvard Business Review, March-April, pp. 93-103, New York.Amasaka, K. 1983. Mechanization for operation depended on intuition and knack – Corrective method for distortion of rear axle shaft, The Japanese Society for Quality Control, The 26th Technical Conference, Nagoya, Aichi, Japan, pp. 5-10.
Womack, J. P. and Jones, D.T. and Roos, D., (1991), The machine that change the world – The story of Lean Production, Rawson/Harper Perennial, New York.
Yamaji, M. and Amasaka, K. 2009. Strategic productivity improvement model for white-collar workers employing Science TQM, The Journal of Japanese Operations Management and Strategy, Vol. 1, No. 1, pp. 30-46.

Chapter 3

Amasaka, Ed. 2003. Manufacturing fundamentals: The application of intelligence control charts–Digital engineering for superior quality assurance, Japanese Standards Association, Tokyo. (in Japanese)
Amasaka, H. and Sakai, H. 1998. Availability and Reliability Information Administration System “ARIM-BL” by methodology in “Inline-Online SQC,” International Journal of Reliability, Quality and Safety Engineering, Vol. 5, No. 1. pp. 55-63.
Amasaka, K. 1988. Concept and progress of Toyota Production System (Keynote lecture), Co-sponsorship: The Japan Society of Precision Engineering, The Japan Society for Technology of Plasticity, The Japan Society for design and Drafting, and Hachinohe Regional Advance Technology Promotion Center Foundation, Hachinohe, Aomori-ken, Japan. (in Japanese).
Amasaka, K. 2000. Partnering chains as the platform for quality management in Toyota, Proceedings of the 1st World Conference on Production and Operations Management, Seville, Spain, pp. 1-13 (CD-ROM).
Amasaka, K. 2001. Quality management in the automobile industry and the practice of the joint activities of the auto maker and the supplier, Japan Small Business Research InstituteA change in the order system such as a part in the manufacturing industry and that correspondence: The condition of the supplier continuance in the automobile industry, Vol. 74 No. 2, Chapter 6, pp. 133-161. (in Japanese)
Amasaka, K. 2002. New JIT, a new management technology principle at Toyota,” International Journal of Production Economics, Vol. 80, pp. 135-144.
Amasaka, K. 2003a. Proposal and implementation of the “Science SQC”, quality control principle, International Journal of Mathematical and Computer Modeling, Vol. 38, No. 11-13, pp. 1125-1136.
Amasaka, K. 2003b. (Special lecture) Digital engineering and production control in a high quality assurance, The Japan Society for Production Management, The 17th Annual Conference, Tutorial Session: The Past, the Present, and the Future of Quality CreationLogic and Digital Engineering of Quality Creation, Gakushuin University, Tokyo. (in Japanese)
Amasaka, K. 2004a. Applying New JIT—A Management Technology Strategy Model at Toyota - Strategic QCD Studies with Affiliated and Non-affiliated Suppliers-, in Proceedings of the Production and Operations Management Society, Cancun, Mexico, pp. 1-11 (CD-ROM).
Amasaka, K. 2004a. Development of “Science TQM”, a new principle of quality management: Effectiveness of strategic stratified task team at Toyota-, International Journal of Production Research, Vol. 42, No. 17, pp. 3691-3706.
Amasaka, K. 2004b. Science SQC, New Quality Control Principle: Quality Control Strategy at Toyota, Springer-Verlag Tokyo.
Amasaka, K. 2004b. The past, present, future of production management (keynote lecture), The Japan Society for Production Management, the 20th Annual Technical Conference, Nagoya Technical College, Japan, pp. 1-8. (in Japanese)
Amasaka, K. 2007. High Linkage Model “Advanced TDS, TPS & TMS”: Strategic development of “New JIT” at Toyota -, International Journal of Operations and Quantitative Management, Volume 13, Number 3, September 2007, pp. 101-121.
Amasaka, K. 2007a. New Japan Production Model, an advanced production management principle: Key to strategic implementation of New JIT, The International Business & Economics Research Journal. Vol. 6, No. 7, pp. 67-79.
Amasaka, K. 2007b. Applying New JIT - Toyota’s global production strategy: Epoch-making innovation in the work environment, Robotics and Computer- Integrated Manufacturing, Vol. 23, Issue 3, pp. 285-293.
Amasaka, K. 2007b. High Linkage Model “Advanced TDS, TPS & TMS”: Strategic development of “New JIT” at Toyota, International Journal of Operations and Quantitative Management, Vol. 13, No. 3, pp. 101-121.
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Sakai, H. and Amasaka, K. 2008. Human-Integrated Assist System for Intelligence Operators, Encyclopedia of Networked and Virtual Organization, Vol. II, G-Pr, pp. 678-687.
Sakai, H., and Amasaka, K. 2007. Development of a robot control method for curved seal extrusion for high productivity in an advanced Toyota production system, International Journal of Computer Integrated Manufacturing, Vol. 20, No. 5, pp. 486-496.
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Yamaji, K., Sakatoku, T. and Amasaka, K. 2008. Partnering Performance Measurement “PPM-AS” to strengthen corporate management of Japanese automobile assembly makers and suppliers, International Journal of Electronic Business Management, Vol. 6, No. 3, pp.139-145.
Yamaji, M. and Amasaka, K. 2007. Proposal and validity of Global Intelligence Partnering Model for Corporate Strategy, “GIPM-CS”, Advances in Production Management Systems, (International IFIP TC 5.7 Conference on Advanced in Production Management System, Linkoping, Sweden), Springer, pp. 59-67.
Yamaji, M. and Amasaka, K. 2009. Strategic Productivity Improvement Model for white-collar workers employing Science TQM, The Journal of Japanese Operations Management and Strategy, Vol. 1, No. 1, pp. 30-46.
Yamaji, M., Sakatoku, T. and Amasaka, K. 2008. Partnering performance measurement “PPM-AS” to strengthen corporate management of Japanese automobile assembly makers and suppliers, International Journal of Electronic Business Management, Vol. 6, No. 3, pp. 139-145.

Chapter 8

Amasaka, K and Sakai, H. 2010. Evolution of TPS fundamentals utilizing New JIT strategy - Proposal and validity of Advanced TPS at Toyota, Journal of Advanced Manufacturing Systems, Vol. 9, Issue. 2, pp. 85-99.
Amasaka, K. 2002. New JIT, A New Management Technology Principle at Toyota, International Journal of Production Economics, Vol. 80, pp.135-144.
Amasaka, K. 2004. Development of Science TQM, a new principle of quality management: Effectiveness of strategic stratified task team at Toyota, International Journal of Production Research, Vol. 42, No. 17, pp. 3691-3706.
Amasaka, K. 2004b. Science SQC, New Quality Control Principle: The Quality Strategy of Toyota, Springer-Verlag, Tokyo.
Amasaka, K. 2005. New Japan Production Method, An innovative production management principle, Proceedings of the 16th Annual Conference of the Production and Operations Management Society, Michigan, Chicago, IL:1-22 (CD-ROM).
Amasaka, K. 2006. Evolution of TPS fundamentals utilizing New JIT Strategy: Toyota’s Simultaneous Realization of QCD Fulfillment Models, Proceedings of the International Manufacturing Leaders Forum, Taipei, Taiwan, pp.1-6 (CD-ROM).
Amasaka, K. 2007. High Linkage Model “Advanced TDS, TPS & TMS”: Strategic development of “New JIT” at Toyota, International Journal of Operations and Quantitative Management, Vol. 13, No 3, pp. 101-121.
Amasaka, K. 2007a. New Japan Production Model, An advanced production management principle: Key to strategic implementation of New JIT, The International Business & Economics Research Journal. Vol. 6, No. 7, pp. 67-79.


Amasaka, K. 2007c. New Japan Model, Science TQM: Theory and application of strategic quality management, Maruzen publishing, Tokyo. (in Japanese)
Amasaka, K. 2008, Strategic QCD studies with affiliated and non-affiliated suppliers utilizing New JIT, Encyclopedia of Networked and Virtual Organizations, Vol. III, PU-Z, pp. 1516-1527.
Amasaka, K. 2008b. Science TQM, a new quality management principle: The quality management strategy of Toyota, The Journal of Management & Engineering Integration, Vol. 1, No. 1, pp. 7-22.
Amasaka, K. 2009. The foundation for advancing the Toyota Production System utilizing New JIT, Journal of Advanced Manufacturing Systems, Vol. 8, No. 1, pp. 5-26.
Amasaka, K. 2013. The development of a Total Quality Management System for transforming technology into effective management strategy, The International Journal of Management, Vol. 30, No. 2, pp. 610-630.
Amasaka, K. 2015. New JIT, New Management Technology Principle, Taylor & Francis, Danvers, MA / CRC Press, Boca Raton, FL.
Amasaka, K. 2016. Innovation of automobile manufacturing fundamentals employing New JIT: Developing Advanced Toyota Production System at Toyota Manufacturing USA, Proceedings of the 5th Conference on Production and Operations Management, P&OM Habana, Cuba, Habana International Conference Center, pp.1-10.
Amasaka, K. 2017. Strategic Stratified Task Team Model for realizing simultaneous QCD fulfilment: Two case studies, Journal of Japanese Operations Management and Strategy, Vol. 7, No. 1, pp. 14-35.
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Amasaka, K. and Sakai, H. 2009. TPS-QAS, New Production Quality management Model: Key to New JIT - Toyota’s global production strategy, International Journal of Manufacturing Technology and Management, Vol.18, No.4, pp. 409-426.
Amasaka, K. and Sakai, H. 2010. Evolution of TPS fundamentals utilizing New JIT strategy: Proposal and Validity of Advanced TPS at Toyota, Journal of Advanced Manufacturing Systems, Vol. 9, Issue 2, pp. 85-99.
Amasaka, K. and Sakai, H. 2011. The New Japan Global Production Model “NJ-GPM”: Strategic Development of Advanced TPS, The Journal of Japanese Operations Management and Strategy, Vol. 2, No. 1, pp. 1-15.
Amasaka, K. Ed. 2012. Science TQM, New Quality Management Principle: The quality management strategy of Toyota, Bentham Science Publisher.
Amasaka, K. Ed. 2012. Science TQM, New Quality Management Principle: The Quality Management Strategy of Toyota, Bentham Science Publisher, Sharjah, UAE / Oak Park, USA / AG Bussum, The Netherlands.
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Sakai, H. and Amasaka, K. 2006. Strategic HI-POS, intelligence production operating system: Applying Advanced TPS to Toyota’s global production strategy, WSEAS Transactions on Advances in Engineering Education, Issue3, Vol. 3, pp. 223-230.
Sakai, H. and Amasaka, K. 2007. Development of a robot control method for curved seal extrusion for high productivity in an advanced Toyota production system, International Journal of Computer Integrated Manufacturing, Vol. 20, No. 5, pp. 486-496.
Sakai, H. and Amasaka, K. 2008. Human-Integrated Assist Systems for intelligence operators, Encyclopedia of Networked and Virtual Iorganizations, Vol. II, No.G-Pr, pp. 678-687.
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Siang, Y. Y., Sakalsiz, M. M. and Amasaka, K. 2010. Proposal of New Turkish Production System (NTPS), Integration and evolution of Japanese and Turkish production system, Journal of Business Case Study, Vol. 6, No. 6, pp. 69-76.
Yamaji, M. and Amasaka, K. 2006. New Japan Quality Management Model, Hyper-cycle model “QA & TQM Dual System” -Implementation of New JIT for strategic Management technology-, Proceedings of the International Manufacturing Leaders Forum, pp.1-6 (CD-ROM).
Yamaji, M. and Amasaka, K. 2007. Proposal and validity of Global Intelligence Partnering Model for Corporate Strategy, “GIPM-CS”, Advances in Production Management Systems, (International IFIP TC 5.7 Conference on Advanced in Production Management System, Linkoping, Sweden), Springer, pp. 59-67.
Yamaji, M. and Amasaka, K. 2008. New Japan Quality Management Model: -Implementation of New JIT for strategic management technology, The International Business & Economics Research Journal, Vol. 7, No. 3, pp. 107-114.
Yamaji, M. and Amasaka, K. 2009, Strategic Productivity Improvement Model for white-collar workers employing Science TQM, The Journal of Japanese Operations Management and Strategy, Vol. 1, No. 1, pp.30-46.
Yamaji, M., Sakai, H. and Amasaka, K. 2006. Intellectual Working Value Improvement Model utilizing Advanced TPS: Applying New JIT, Toyota’s global production strategy, Proceedings of the International Applied Business Research Conference, Cancun, Mexico, pp.1-10 (CD-ROM).
Yamaji, M., Sakai, H. and Amasaka, K. 2007. Evolution of technology and skill in production workplaces utilizing Advanced TPS, The Journal of Business & Economics Research, Vol. 5, No. 6, pp. 61-68.
Yeap, Y. S., Murat. M. S. and Amasaka. K., 2010. Proposal of New Turkish Production System, NTPS, Integration and Evolution of Japanese and Turkish Production System, Journal of Business Case Study, 6, 2010, pp. 69-76.

Chapter 9

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Amasaka, K. 2007. High Linkage Model “Advanced TDS, TPS & TMS”: Strategic development of “New JIT” at Toyota, International Journal of Operations and Quantitative Management, Vol. 13, No. 3, pp. 101-121.
Amasaka, K. 2007. The validity of TDS-DTM: A Strategic methodology of merchandise development of New JIT - Key to the excellence design Lexus, International Business & Economics Research Journal, Vol. 6, No. 11, pp. 105-116.
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Audience:
1) For University and Technical college (Industrial Engineering, Production Engineering, Operations Management, Information Management, Business administration, management engineering. MBA and SCM) : Researcher and educator (Professor, Associate professor, instructor and assistant), Students of Undergraduate, graduate school (master and doctor)
2) For Enterprise and laboratory (Advanced countries and developing countries): Business administration person( President, an advanced officer, senior executive, professional engineer and special staff, Manager and supervisor
3) Type of industry (: Manufacturing, Automobile and SCM)
4) Consultant, private tutoring school instructor and a general education seminar

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