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Taiichi Ohno (1912-1990) was born in Dalian, in eastern China. He had joined Toyota Automatic Loom Works between the wars. This was the first business of the Toyoda family until it was sold to a British company, Platt Brothers, and the family decided to invest the money that it had gained from the sale in manufacturing motor cars. Ohno switched to work as a production engineer for Toyota, a car company, towards the end of the second world war, at a time when its productivity was way below that of America’s mighty Detroit industry. Toyota’s boss declared that it “must catch up with America within three years”. Ohno decided there was no reason other than inefficiency and wastefulness why Toyota’s productivity should be any lower than that of Detroit. Hence he set out to eradicate inefficiency and eliminate waste in the part of the production process that he was responsible for.
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This became the core of the so-called Toyota Production System (TPS) that he and others subsequently developed between the mid-1940s and the mid-1970s. Several elements of this system have become familiar in the West: for example, muda (the elimination of waste), jidoka (the injection of quality) and kanban (the tags used as part of a system of just-in-time stock control). Three men were especially prominent in creating the Toyota Production System: Sakichi Toyoda; his son, Kiichiro Toyoda; and Taiichi Ohno. Sakichi Toyoda was the inventor of automatic looms who founded the Toyota Group. He invented a loom in 1902 that would stop automatically if any of the threads snapped. His invention opened the way for automated loomworks where a single operator could handle dozens of looms. The principle of designing equipment to stop automatically and call attention to problems immediately is crucial to the Toyota Production System.
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