What is the Toyota track system?

At its core, there is no official term called the “Toyota track system.” The phrase most often points to Toyota Production System (TPS), Toyota’s renowned lean manufacturing framework that guides how the company designs, builds, and delivers products. If you meant something else—such as a vehicle’s traction or track-related feature—see the sections below for clarification.

Clarifying the term

The name most closely associated with Toyota’s manufacturing success is the Toyota Production System (TPS). It underpins Toyota’s approach to efficiency, quality, and continuous improvement, and has influenced lean manufacturing practices worldwide. If you were asking about a mechanical track or traction feature on Toyota vehicles, those are separate topics covered later in this article.

Origins and evolution

TPS emerged in postwar Japan as Toyota sought to compete with limited resources. Engineers led by Taiichi Ohno and other Toyota managers developed a system to reduce waste, shorten production lead times, and empower workers. Over time, TPS evolved into what many now call The Toyota Way, a broader management philosophy that blends operational practices with cultural principles of kaizen (continuous improvement) and respect for people.

Core principles of TPS

The system is often summarized around two central pillars plus enabling practices that sustain flow and quality on the factory floor.

• Just-in-Time (JIT) production — delivering the right item in the right amount at the right time


• Jidoka (automation with a human touch) — automation that can stop the line to prevent defects


• Kanban — visual signals that trigger replenishment and production


• Kaizen — continuous improvement at all levels of the organization


• Heijunka — production leveling to smooth out workload and demand


• Standardized work — documented, repeatable methods to ensure consistency


• 5S and workplace organization — sorting, simplifying, sweeping, standardizing, and sustaining


• Respect for people and strong supplier relationships — collaborative problem solving across the value chain

These elements aim to minimize waste, reduce inventory, shorten lead times, and raise product quality across production lines and supply networks.

Key tools and practices on the shop floor

To implement TPS on the factory floor, Toyota relies on a toolkit of methods and routines that translate principles into daily work and decision making.

• Pull systems with Kanban signaling — work is started in response to actual demand from downstream processes


• Andon and visual management — real-time alerts of problems on the line


• Poka-yoke (mistake-proofing) — simple mechanisms to prevent human error from becoming defects


• Heijunka and takt-time planning — smoothing production pace to match demand


• Standardized tasks and Kaizen cycles — stable processes with ongoing refinements


• Close supplier integration and Just-In-Time logistics — tight coordination with suppliers to maintain flow

These tools help create reliable production flow, rapid problem detection, and a culture of continuous improvement across teams and suppliers.

Other uses of the term and alternative meanings

In casual discussions, “track system” can refer to vehicle technologies related to traction or chassis behavior. Toyota’s traction-related electronics include TRAC (Traction Control) and Vehicle Stability Control (VSC), which help maintain grip and stability during driving. These vehicle systems are separate from TPS and apply to individual cars rather than a company-wide manufacturing framework.

Summary

What is often called the “Toyota track system” is typically the Toyota Production System (TPS)—a lean manufacturing framework built around Just-in-Time, Jidoka, Kanban, and Kaizen, designed to minimize waste, improve quality, and boost efficiency. The term can be misleading when used outside manufacturing; if you had a different concept in mind (for example, traction-control features on Toyota vehicles), those are distinct technologies with their own terminology.

How does Toyota A Trac work?

Toyota's A-TRAC (Active TRAC) is an off-road traction control system that uses the anti-lock brakes to apply brakes to a wheel that is spinning freely, which redirects power to the wheel on the same axle that has traction. It works automatically at low speeds when in four-wheel drive low (4LO4 cap L cap O4𝐿𝑂) to help a vehicle move through slippery conditions like sand, mud, or snow, by simulating a locking differential. To use it, you must be in 4LO4 cap L cap O4𝐿𝑂, and the system engages automatically when a wheel starts to slip, applying the brakes to that wheel to transfer power to the one with grip.
 
This video explains what A-TRAC is and how it works in a Toyota 4Runner: 58sDriven CompanionYouTube · Nov 26, 2020
How A-TRAC works

• When a wheel starts to lose traction and spin, A-TRAC detects the difference in wheel speed. 
• It automatically applies the brakes to the spinning wheel. 
• This action creates resistance on the spinning wheel, allowing the axle to send power to the wheel that has traction. 
• The brakes pulsate to allow power to be transferred to the opposite wheel, helping the vehicle move forward. 

You can watch this video to see a demonstration of how A-TRAC works on a steep hill: 56sJason SamkoYouTube · Feb 15, 2024
Key things to know

• Engaging A-TRAC: The system must be engaged by shifting into four-wheel drive low (4LO4 cap L cap O4𝐿𝑂) and pressing the "A-TRAC" button (on some models, it engages automatically in 4LO4 cap L cap O4𝐿𝑂 on others). 
• Engine power is needed: The system needs power from the engine to work, so you may need to apply throttle to create wheel spin to activate the brakes. 
• Low speed system: A-TRAC is designed to be used at low speeds, generally below 555 mph. 
• Best for getting unstuck: It is most effective when you are already stuck or need to accelerate from a complete stop in a low-traction situation. 
• Loud operation: You may hear grinding or robotic sounds when A-TRAC is active, which is normal for the system. 
• Replaces a traditional locker: It provides similar functionality to a locking differential, but uses the ABS system to apply brakes instead of a mechanical lock. 
• Different from Crawl Control: While both systems use brakes and throttle, A-TRAC's primary function is to emulate a locking differential, whereas Crawl Control actively manages the throttle to maintain a constant speed for the vehicle as a whole. 

Should my trac be on or off?

For everyday driving, leaving traction control on is the safer default. Turn it off only for short, specific tasks where wheel slip is needed or for skilled performance driving in controlled environments; otherwise the increased risk to stability and control outweighs potential benefits.

What is the Trac system on a Toyota?

Toyota's TRAC system is a form of traction control that prevents wheel spin on slippery surfaces by automatically reducing engine power and applying the brakes to individual wheels. An older and more off-road oriented system called A-TRAC (Automatic Traction Control) operates when the vehicle is in 4WD low and acts like an electronic limited-slip differential by sending power to the wheels with traction. Both systems enhance safety and control, but you may need to turn TRAC off to get unstuck from situations like deep snow or mud.
 
This video explains what traction control is and why you would turn it off: 59sToyotaJeff ReviewsYouTube · Oct 31, 2018
How TRAC works

• Standard TRAC: When a wheel starts to spin, the system detects the slip and intervenes by reducing engine throttle and applying a small amount of brake pressure to the spinning wheel. This helps maintain control, especially during acceleration on wet or icy roads. 
• A-TRAC (Automatic Traction Control): This system is designed for off-road use and activates only in 4WD low. It works by sensing a spinning wheel and applying the brakes to it, which transfers power to the other wheels that are still on the ground, helping the vehicle crawl over obstacles or through sand, snow, or mud. 

When to use and disable TRAC

• On-road: TRAC is a valuable safety feature that should generally be left on for most driving conditions to help maintain traction and stability. 
• Off-road (A-TRAC): Leave A-TRAC on for difficult off-road situations where you need maximum grip, such as on rocky trails or steep, slippery inclines. 
• Disabling TRAC: You may need to turn the system off if your vehicle is stuck in deep snow, mud, or sand. The system's attempt to reduce power can prevent the wheels from spinning, which is sometimes necessary to "rock" the vehicle out of a stuck position. To disable it, you typically press and hold the "TRAC OFF" or "VSC OFF" button for three seconds, which will illuminate the corresponding indicator light on the dashboard. 

You can watch this video to see how to turn off traction control on a Toyota: 1mAuto V Fix YouTube · Mar 23, 2023

What does the trac system do?

While you have to manually turn this feature on and off, once it is on, it automatically detects wheel spin and distributes torque between front and rear wheels to suppress unnecessary wheel spin and control skidding.