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he Toyota Production System (TPS) is the foundation of Lean methodology, influencing industries worldwide. This series offers an in-depth understanding of TPS, focusing on its core pillars:
TPS Overview
Heijunka (Production Leveling)
Just-in-Time (JIT)
Poka-Yoke (Error-Proofing)
By exploring these elements, you’ll gain insights into the mindset that drives world-class performance.
Understand the foundational principles and cultural aspects of TPS:
History and evolution of TPS
The twin pillars: JIT and Jidoka
Respect for people and continuous improvement
14 Toyota Management Principles
TPS vs Traditional Manufacturing
Learn how to flatten demand variation and level production schedules:
What is Heijunka and why it’s critical in Lean
Tools: Heijunka Box, pitch, and leveling techniques
Aligning Heijunka with takt time
Heijunka in high-mix, low-volume environments
Case study: Production leveling in assembly and servicessixsigmadsi.com
Implement systems that produce only what’s needed, when it’s needed:
Principles of JIT and pull-based production
Reducing lead time, batch sizes, and inventory
Visual control and Kanban integration
JIT in manufacturing, service, and logistics
Common barriers to JIT and how to overcome them
Master the art of mistake-proofing with practical, low-cost tools:
What is Poka-Yoke and its role in TPS
Types: Contact, Motion, Warning, Automatic Shutoff
Examples from shop floor, software, healthcare
How to implement Poka-Yoke systems
Idea generation & audit templates included
A comprehensive understanding of TPS philosophy, structure, and tools
Techniques to reduce waste and variability using Heijunka and JIT
Methods to integrate Poka-Yoke for defect prevention
Strategies to embed the Toyota Way into your own Lean culture
Approaches to build flow, stability, and quality into every process
Holistic TPS Understanding: Gain an integrated view of how JIT, Jidoka via Poka-Yoke, and Heijunka work together to create a world-class operational system.
Expert-Led Training: Learn from experienced Lean and TPS consultants with a proven track record.
Practical & Strategic Insights: Apply TPS principles effectively within your organization through case studies and practical exercises.
Drive Transformative Results: Equip your team to reduce waste, improve quality, and enhance flow.
Cultivate a Lean Culture: Empower your team to drive continuous improvement and sustainable excellence.
This series is tailored for:
Operations & Production Leaders
Lean Managers & Continuous Improvement Professionals
Process Engineers & Industrial Engineers
Supply Chain & Logistics Managers
Anyone Leading or Participating in Lean Transformations
100% Online + Lifetime Access
Industry Case Studies + Examples
Templates for Poka-Yoke, Heijunka, JIT Planning
Language: English + Hinglish
Certificate of Completion from AIG
Access to AIG’s Lean Mastery Community
Total Duration: 10–12 Hours
Mode: Self-paced (Optional Live Q&A Access)
Access Validity: Lifetime
Program Fee: ₹XXX (All Inclusive)
Introductory Offer: Get 35% Off for Early Registrations
TPS Model Infographic
JIT Implementation Planner
Heijunka Box Template (Excel)
Poka-Yoke Checklist
AIG’s TPS Deployment Guide (PDF)
Email: info@aigpl.com
Phone: +91-783-865-6001
WhatsApp Support: Available
Group Discounts & Corporate Access: Available
40 hours of high quality Instructor led training.
Hands on training on Data Analysis using Minitab and live project data.
Mentor 5 Six Sigma projects to enable certification.
At AIG get trained on lean six sigma master black belt by practicing Master Black Belts.
Classes at AIG can be planned as per your availability. You can attend classes in multiple of 2 hours i.e. classes can be arranged for 2,4,6,8 hours.
You can pay your fee in installments or we can help setup EMI from the bank.
We use Technology to make our relationship more transparent and accountable. You can download our Android App for ease.
Get access to 100s of completed lean six sigma projects, articles and participate in discussions with industry experts.
We provide support to help you get placed. We help with interview preparation, resume building and alumni network for placement.
The TPS Deep Dive Series goes beyond basic Lean tools to explore the core philosophy, principles, and practices of the original Toyota Production System (TPS). Unlike surface-level Lean courses, this program focuses on how tools like Just-in-Time, Heijunka, and Poka-Yoke are interconnected within a culture of continuous improvement and respect for people — the true essence of Lean.
This series is ideal for professionals in manufacturing, healthcare, logistics, IT, and service industries who want to understand and apply Lean at a strategic level. It’s especially valuable for Lean practitioners, operations leaders, continuous improvement teams, and anyone driving or supporting a Lean transformation.
ou’ll gain actionable knowledge and downloadable tools for:
Heijunka (production leveling)
JIT planning
Poka-Yoke implementation
TPS system design and cultural alignment
The program includes case studies, templates, and worksheets to help you immediately apply TPS concepts to real-world scenarios.
The TPS Deep Dive Series is delivered 100% online with lifetime access. It’s a self-paced program totaling approximately 10–12 hours, with optional live Q&A sessions and community support. You can learn anytime, anywhere, at your own pace.
Upon successful completion of the series, you’ll receive an AIG Certificate of Completion, which recognizes your advanced understanding of TPS. This certificate is a strong addition to your professional credentials, especially if you're involved in Lean, operations, or process excellence roles.
Lean Six Sigma Consultant
Neha Sharma, a certified MBB, PMP and LA for several ISO Standards has had experience of training greater than 1000 Six Sigma Professionals for Black Belt and Green Belt programs. She has helped several firms with success change implementations.
LSS MBB, LA ISO 9001, 27001, 14001, 45001, 20000-1, 22301. 22001. IATF, 31000, ITIL Practioner, Prince2 Practioner, Scrum Master Etc.
CEO and Principal Consultant @AIG, Pranay has had an illustrious career of over 2.5 decades helping companies become profitable and organized. He has been instrumental in the setup of Management Systems, Lean Six Sigma Implementation, Project Mgmt framework, etc. He has mentored more than 20000 professionals in Lean Six Sigma, ISO Standards, Project Management, Digital Transformation, etc.
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