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TOYOTA

FORERUNNER IN LEAN MANUFACTURING
by

Karen Hanneman

on 25 October 2012

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Transcript of TOYOTA

photo credit Nasa / Goddard Space Flight Center / Reto Stöckli JUST IN TIME WORLD CLASS MANUFACTURING TOYOTA COMBINES ATTITUDES, THEMES AND SPECIFIC TECHNIQUES INTO A SYSTEM FOR MANUFACTURING TOYOTA PRODUCTION SYSTEM
(TPS) MATERIAL
TIME
IDLE EQUIPMENT
INVENTORY ELIMINATE ALL WASTE EMPHASES ON THE PARTICIPATION OF ALL EMPLOYEES IN TEAMS

FOR MOTIVATION
WORK MANAGEMENT
PROBLEM SOLVING PEOPLE AND TECHNOLOGY A SMALL STOCK
OF ALL ITEMS NEEDED IN A DEDICATED AREA WITH A FIXED ALLOWED SPACE SCHEDULING SYSTEMS REDUCES ERRORS AND THE COST OF RECTIFYING THE END TOYOTAS WAY OF MAKING THINGS
IS BEING SPREAD THROUGH THE WORLD AS THE TOYOTA WAY FORM A SYSTEM USING THE
STRENGTHS OF EACH AND MINIMIZE THE WEAKNESSES WORK CELLS Toyota cells have a single product or a highly similar group. The process is linear, sequential and identical for all products in
the group. WORK CELLS
MANUFACTURE SIMILAR PRODUCTS SELF CONTAINED WITH ALL
EQUIPMENT AND MATERIALS NEEDED PEOPLE ARE CLOSE SO
COMMUNICATION
IS EASY IMPROVES MATERIAL FLOW
SCHEDULING
AND SUPERVISION NEW MATERIALS ARE BROUGHT IN
ONLY AS OLD ONES
ARE USED FREQUENT REPLENISHMENT
TO KEEP MATERIALS INVENTORY LOW, AND
ALSO ALWAYS STOCKED FOCUS ON PREVENTING ERRORS
AT THE SOURCE EMPLOYEES DO THEIR OWN SET UP AND WATCHING FOR ERRORS AND
RECTIFY IMMEDIATELY TOYOTA MAKES CARS AND TRUCKS AND
SUVS AS WELL AS OTHER TRANSPORTATION
VEHICLES AND ACCESSORIES. TOYOTA IS ALSO
WORKING ON ROBOTS FOR CONSUMER USE,PARTICULARLY
SEVERAL VARIATIONS OF ROBOTS FOR USE BY THE HANDICAPPED At Toyota, each process is specified with
detailed instructions. For example, when assemblers install seats with four bolts,
the bolts are inserted and tightened in a
precise sequence. Every worker installs
them in the same way, every time. LINKS THE WAY WORK IS DONE AND THE RESULTS At Toyota every operation, sends its products to
the next step in production directly using methods that
are clear and precise. It eliminates the need for separate warehouses and separate people or departments whose
only function is inventory management. Toyota has U-shaped workcells, every piece of
finished product has been through the same
equipment and the same process. It improves
consistency, makes trouble-shooting easier and
simplifies material handling and scheduling. WWW.TOYOTA.COM Toyota has failure tests that
automatically signal deviations
for every activity, connection and flow
path. TOYOTA FORK LIFT TRUCK TOYOTA'S WHEEL CHAIR OF THE FUTURE TOYOTA'S PARTNER ROBOT OTHER FORMS OF TRANSPORTATION WORK CELLS
TYPICALLY HAVE 3-12 PEOPLE
AND 5-15 WORKSTATIONS TOYOTA ORGANIZES ITS SUPPLIERS INTO CLUSTERS, BASED ON LOCATION AND PICKS UP AND DELIVERS ITS SUPPLIES THEM SELF TO THEIR PLANTS. TOYOTA SENDS OUT 13 WEEK FORECASTS TO THEIR SUPPLIERS, TO PROVIDE GUIDANCE FOR FUTURE ORDERS. This prevents products with unacceptable
quality from continuing in the process. Examples are detectors that detect
missing components, and automatic
gages that check each part and visual
alarms that tell when stocks of
materials are getting low.
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