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Toyota Motor Manufacturing (TMM)
Toyota Motor Manufacturing (TMM)
TOYOTA - the Largest Car Manufacturer
TOYOTA - the Largest Car Manufacturer
Toyota Camry Then (1992) and Now (2007)
Toyota Camry Then (1992) and Now (2007)
Toyota Georgetown Plant
Toyota Georgetown Plant
Georgetown Plant
Georgetown Plant
Georgetown Plant www
Georgetown Plant www
History of the Plant
History of the Plant
Overview of the Production Process
Overview of the Production Process
What is Doug Friesen’s problem
What is Doug Friesen’s problem
Doug Friesen’s problem
Doug Friesen’s problem
What are the Seat Problems
What are the Seat Problems
Seat Problems
Seat Problems
A Test of Japanese
A Test of Japanese
A Test of Japanese
A Test of Japanese
1. Line Stoppage
1. Line Stoppage
Continue to violate Jidoka
Continue to violate Jidoka
Continue to violate Jidoka
Continue to violate Jidoka
2. Crowding in the overflow area
2. Crowding in the overflow area
3. Assembly area
3. Assembly area
3. Assembly area
3. Assembly area
4. Supplier
4. Supplier
5. Seat Mismatches: RFID as a potential fix
5. Seat Mismatches: RFID as a potential fix
How much of TPS is culture
How much of TPS is culture
Toyota is worried of its culture being diluted with fast overseas
Toyota is worried of its culture being diluted with fast overseas
NUMMI
NUMMI
26
26
History/Products
History/Products
Workers
Workers
Capacity
Capacity
Work Flow
Work Flow
Just in time
Just in time
Creative Tool / Work Place Design
Creative Tool / Work Place Design
Home of Tundra in San Antonio
Home of Tundra in San Antonio
Toyota Way of Finishing a Class: -
Toyota Way of Finishing a Class: -
Appendix
Appendix
All of Toyota Plants in the North America
All of Toyota Plants in the North America
All of Honda Plants in the North America
All of Honda Plants in the North America
All of Nissan Plants in the North America
All of Nissan Plants in the North America
All of Hyundai-Kia Plants in the North America
All of Hyundai-Kia Plants in the North America
All of Mercedes and BMW Plants in the North America
All of Mercedes and BMW Plants in the North America
All of Ford Plants in the North America
All of Ford Plants in the North America
All of Chrysler Plants in the North America
All of Chrysler Plants in the North America
All of GM Plants in the North America
All of GM Plants in the North America

Презентация на тему: «Toyota Motor Manufacturing (TMM)». Автор: Metin. Файл: «Toyota Motor Manufacturing (TMM).ppt». Размер zip-архива: 2761 КБ.

Toyota Motor Manufacturing (TMM)

содержание презентации «Toyota Motor Manufacturing (TMM).ppt»
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1 Toyota Motor Manufacturing (TMM)

Toyota Motor Manufacturing (TMM)

A case on Just-in-time and Total Quality Management

1

2 TOYOTA - the Largest Car Manufacturer

TOYOTA - the Largest Car Manufacturer

2

3 Toyota Camry Then (1992) and Now (2007)

Toyota Camry Then (1992) and Now (2007)

3

4 Toyota Georgetown Plant

Toyota Georgetown Plant

4

To Cincinnati

To Dallas

5 Georgetown Plant

Georgetown Plant

5

6 Georgetown Plant www

Georgetown Plant www

toyotageorgetown.com

6

7 History of the Plant

History of the Plant

Ground breaking, May 1986 First Car, May 1988 Fujio Cho named the second president, Dec 1988 1 millionth Camry, Oct 1993 2 millionth Camry, Apr 1997 Camry #1 selling car in the US in 97, 98, 99, 00 Gary Convis named fifth president, Apr 2001 Camry #1 selling car in the US in 02, 03, 04, 05 Sixth generation Camry starts, Feb 2006

7

8 Overview of the Production Process

Overview of the Production Process

???? manufacturing, ???? ????, used for panels, bumpers, connections, protections ????, shaping the steel coils into body parts Uses ???? dies (analogous to cookie cutters) ???? of the body ???? ???? Trim Heater, A/C, Wiring Bumpers, Headliners Chassis, underbody work, engine marriage Final line, air bags, instrument panels, seats Final test, ????

8

9 What is Doug Friesen’s problem

What is Doug Friesen’s problem

9

10 Doug Friesen’s problem

Doug Friesen’s problem

A ???? run ratio of ??%: Number assembled actually / Number could be assembled Line is stopped due to defectives by pulling an andon cord Too often or too rare? ????, defective car-seat combinations sent downstream Defectives are due to ???? rotation, product ????, ???? ????/???? design A substantial number of cars off-line with ???? seats or ???? seats. Some cars wait ???? days for seats in the ???? area although ???? commits to send seats in a single shift. Is the reordering of Ex.9 form readable? Cars served FIFO? What is the problem with the seats?

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11 What are the Seat Problems

What are the Seat Problems

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12 Seat Problems

Seat Problems

???? ???? ???? ????

More problems with the front or back seat?

12

13 A Test of Japanese

A Test of Japanese

Andon Ikko-nagashi Heijunka Jidoka Kaizen Kanban Muda Poka-yoke Takotei-mochi Tsukurikomi

What is violated at TMM?

13

14 A Test of Japanese

A Test of Japanese

Ikko-nagashi: Lot size of one Heijunka: Production smoothing to end up with a level plan Jidoka: Do not pass the defects to downstream Takotei-mochi: Worker flexibility Tsukurikomi: Built-in quality inspection

14

15 1. Line Stoppage

1. Line Stoppage

Setting of the stage: A worker pulls the andon cord, music starts, team leader comes. TL: - What is the problem? W: - …………. TL: Decides how long the line should stop: 1 Cycle=?? seconds or more. If the problem is severe, TL calls the group leader.

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16 Continue to violate Jidoka

Continue to violate Jidoka

Costs of line stoppage Stopping for 1 cycle of 57 seconds Loss of revenue by one car Loss of profit Overtime can be used to recover

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17 Continue to violate Jidoka

Continue to violate Jidoka

Costs of line Stopping for 1 cycle of ?? seconds Loss of revenue by one car, $??,??? Deduct costs of ??% Loss of profit of $?,??? Overtime can be used to recover Cost of ?? seconds of overtime ??*??*??/????=$?.???/worker How many workers stop and do overtime? 1 team, 1 group, assembly line, paint line, …, entire plant? Depends on the ????? inventory between work centers and the length of the stoppage. Ikko-nagashi couples work centers: Stopping one is stopping all.

17

18 2. Crowding in the overflow area

2. Crowding in the overflow area

Can you read the reorder form in Exhibit 9? Computerize the information flow between TMM and ???? ? What is the benefit of dedicating an ???? area specific to seat problems? Dealing with mistakes efficiently vs. Eliminating mistakes

18

19 3. Assembly area

3. Assembly area

Job rotation, a problem source or a fix? Is Takotei-mochi possible without rotation? Hook, now made of ???? as opposed to ???? Personal experience: ???? interior front door handles in my 94 Corolla $50,000 to improve the hook design Build a seat safety inventory to reduce mismatches?

19

20 3. Assembly area

3. Assembly area

Job rotation, a problem source or a fix? Empowering the ????, ???? work force Boredom is a source of errors, Reasonable ???? improve productivity Hook, now made of ???? as opposed to ???? $50,000 to improve the hook design Distribute the cost to cars (1 broken hook per shift)*(2 shifts per day)*(1000 days for this Camry generation) Cost per car is $??, reasonable? What if the hook problem continues after the redesign? Investigate/respond to hook design change Why does not Japanese plant experience the same problem? Does TPS work better in Japan? Does TPS work only in Japanese culture? Build a seat safety inventory to reduce mismatches

20

21 4. Supplier

4. Supplier

Seat quality coming down At least for the new models Addition of Camry Wagon and more types of seats Who is responsible for the seat defects The supplier? The transporter? The TMM receiving? Sharing the responsibility to find the root cause of the seat defects

21

22 5. Seat Mismatches: RFID as a potential fix

5. Seat Mismatches: RFID as a potential fix

See Exhibit 6 for the layout ???? comes from main line ???? comes from a feeder line Both ???? and ???? are RFID tagged When the tags do not match, the workers are alerted This eliminates “some” errors Implemented in conjunction with a seat supplier according to ChainLink Research (www.chainlinkresearch.com) webinar on January 10, 2007.

22

23 How much of TPS is culture

How much of TPS is culture

How much of it is science?

23

24 Toyota is worried of its culture being diluted with fast overseas

Toyota is worried of its culture being diluted with fast overseas

growth

“… the hardest thing for Toyota’s new American employees to accept: those colored bar [performance] charts against a white bulletin board, in plain view for all to see.” Latondra Newton, Toyota Employee in Erlanger, KY New York Times Business Feb 15, 2007.

Aspiring Toyota factory leaders attend Toyota Technical Skills Academy (high school) in Toyota City, Japan. They study mechanical drawing/design . A separate institution, Toyota Institute, prepares executives for Toyota Way. The institute sends off its executives to offices around the world as missionaries.

24

25 NUMMI

NUMMI

based on a trip on Nov 19, 2002

25

26 26

26

Railway Tracks To Oakland Harbor

To Fremont

To San Jose

27 History/Products

History/Products

Late 70’s oil crisis GM closes Fremont, CA plant firing 6000 in 1982 Toyota approaches GM to set up Toyota production system at a GM plant, United Auto Workers accepts the deal GM and Toyota put together $400M in 1984. GM is the landlord, it owns the infrastructure Toyota is the tenant Nummi = New United Motor Manufacturing, Inc is born in 1984 as the unique example of a Toyota – GM joint venture Products: Toyota Corolla, Tacoma Trucks, Pontiac Vibe (Toyota bottom, GM top) and Toyota Voltz (Toyota bottom, GM top, sold in Japan) , GM Prism until 13/12/01

27

28 Workers

Workers

Nummi has about 4500 unionized workers Workers are under two types: Production, high school graduates Maintenance Workers work in teams of 4-6 Workers in a team rotate the tasks every 1-3 hours Team leader is responsible for the rotation. Team leader withdraws parts from the inventory (every 1-2 hours) and provides the tools as necessary Workers make $17 per hour

28

29 Capacity

Capacity

Nummi has a cycle time of 60 seconds for Corolla, 1 body 82 seconds for Tacoma, 3 bodies only cabin is produced at Nummi, the bottom and the back are bought from suppliers Nummi works in two shifts I: 6:00-14:30, II: 16:30-1:00 Each shift has 1 hour lunch/dinner break Starting the first shift at 6:00 workers avoid heavy morning traffic Two hours between shifts I and II is to allow for overtime after the first shift when necessary

29

30 Work Flow

Work Flow

Stamping: Forming metal (side, back, front) panels with presses Body & Weld: Putting panels together Paint: Paint inspection is the current bottleneck Primer body paint applied by robots (chemically hazardous task) Door jambs painted manually Plastics: Making bumpers, inside panels Assembly: Putting in tires, engine, seats, bumpers, harnessing. Cars , trucks on 2 km , 0.8 km conveyors Cars contain Building manifest = BOM = Ingredients list at every step of these operations

30

31 Just in time

Just in time

Kaizen: continuous improvement Kanban: replenishment every 1-2 hours Jidoka: Assure 100% quality. Otherwise pull the Andon chord 1000 times per shift 9% of line stops are longer than 30 seconds Line stops longer than an hour once every month Muda: Waste to be eliminated Genchi Genbutsu: Go to the source to learn and to solve the problems This Japanese terminology is all over the boards in the plant

31

32 Creative Tool / Work Place Design

Creative Tool / Work Place Design

Die change at the stamping in 3 hours Tilted storage bins for ease of access Collapsing storage boxes when empty To reduce the empty box storage requirements in trucks returning to suppliers, say in Indiana These boxes save about $10M annually The worker who suggested the boxes earned several thousand points. 1 point = $1. More info www.nummi.com

32

33 Home of Tundra in San Antonio

Home of Tundra in San Antonio

33

To San Antonio by I-35

I-35 & I-410 Intersection Southwest of San Antonio

I-410 Loop

34 Toyota Way of Finishing a Class: -

Toyota Way of Finishing a Class: -

????? !

34

35 Appendix

Appendix

Where is your favorite brand manufactured?

35

36 All of Toyota Plants in the North America

All of Toyota Plants in the North America

36

Toyota. Cambridge Corolla, Matrix, Lexus, Rav4

Toyota-Subaru. LaFayette Camry

Nummi: Toyota-GM. Freemont. Corolla, Tacoma, Pontiac Vibe

Toyota. Princeton Tundra, Suquoia, Sienna

Toyota. Georgetown Avalon, Camry, Solara

Toyota. Long Beach Hino

Toyota. Blue Springs Highlander

Toyota. Tijuana, Mexico Tacoma

Toyota. San Antonio Tundra

37 All of Honda Plants in the North America

All of Honda Plants in the North America

37

Honda. Alliston, Ca. Civic, Acura, Odyssey, Pilot, Ridgeline

Honda. Decatur TBO in 2008

Honda. Marysville Accord, Acura

Honda. Lincoln Odyssey, Pilot

Honda. El Salto, Me Accord

38 All of Nissan Plants in the North America

All of Nissan Plants in the North America

38

Nissan. Smyrna Frontier, Xterra, Altima, Maxima, Pathfinder

Nissan. Canton Quest, Armada, Titan, Infiniti, Altima

39 All of Hyundai-Kia Plants in the North America

All of Hyundai-Kia Plants in the North America

39

Kia. LaGrange TBO in 2009

Hyundai. Montgomery Sonata, Santa Fe

40 All of Mercedes and BMW Plants in the North America

All of Mercedes and BMW Plants in the North America

40

BMW. Spartanburg Z4, X5, X6 M roadster, coupes

Mercedes. Tuscaloosa M, R classes

41 All of Ford Plants in the North America

All of Ford Plants in the North America

Ontario, Michigan, Illinois, Indiana, Ohio in Focus

41

Ford. Oakville, Ca. Edge, Lincoln MKX

Ford. Dearborn F-150, Lincoln Mark LT

Ford. Saint Paul Ranger, Mazda B series

Ford. Saint Thomas, Ca. Crown Victoria, Grand Marquis

Ford. Flat Rock Mustang, Mazda 6

Ford. Wayne Focus, Expedition, Lincoln Navigator

Ford. Chicago Taurus, Mercury Sable

Ford. Avon Lake Ford E Series

Ford. Kansas City Escape, Escape Hybrid, Mazda Tribute, Mercury Mariner, F-150

Ford. Louisville F-250, F-550, Explorer, Mercury Mountaineer

Ford. Hermosillo, Mex. Ford Fusion, Lincoln MKZ, Mercury Milan

Ford. Cuatitlan, Mex. F-150, 250, 350, 450, 550,Ikon

42 All of Chrysler Plants in the North America

All of Chrysler Plants in the North America

Ontario, Michigan, Illinois, Indiana, Ohio in Focus

42

Chrysler. Sterling Heights Dodge Avenger, Chrysler Sebring

Chrysler. Brampton, Ca Chrysler 300, Dodge Challenger, Dodge Charger

Chrysler. Warren Dodge Ram, Dakota, Mitsubishi Raider

Chrysler. Detroit-Jefferson North Jeep Grand Cherokee and Commander

Chrysler. Detroit-Conner Ave. Dodge Viper, SRT 10 Roadster

Chrysler. Windsor, Ca Dodge Grand Caravan, Chrysler Town

Chrysler. Newark Dodge Durango, Chrysler Aspen Will close in 2009

Chrysler. Belvidere Dodge Caliber, Jeep Compass, Jeep Patriot

Chrysler. Toledo Jeep Liberty, Dodge Nitro

Chrysler. Fenton-North Dodge Ram

Chrysler. Fenton-South Grand Voyager, Grand Caravan, Cargo Van

Chrysler. Saltillo, Mex. Dodge Ram

Chrysler. Toluca, Mex. Chrysler PT Cruise, Dodge Journey

43 All of GM Plants in the North America

All of GM Plants in the North America

Ontario, Michigan, Illinois, Indiana, Ohio in Focus

43

GM. Arlington Chevy Tahoe, Suburban, GMC Yukon, Cadillac Escalade

GM. Oshawa, Ca Chevy Impala, Buick Allure, Chevy Silverado, GMC Sierra. Trucks will stop in 2009.

GM. Orion Pontiac G6, Chevrolet Malibu

GM. Lansing-Grand River Cadillac E-SRX

GM. Lansing-Delta Township Buick Enclave, Saturn Outlook, GMC Acadia

GM. Flint GMC Sierra, Chevy Silverado, Chevy - GMC medium trucks.

GM. Pontiac Chevy Silverado, GMC Sierra

GM. Detroit Buick Lucerne, Cadillac DTS

GM. Janisville Chevy Tahoe, Suburban, GMC Yukon Will stop in 2010

GM. Wilmington Saturn L series, Pontiac Solstice

GM. Fort Wayne Chevy Silverado, GMC Sierra

GM. Fairfax Chevy Malibu, Malibu Maxx, Saturn Aura

GM. Bowling Green Cadillac XLR, Chevy Corvette

GM. Moraine Chevy Trailblazer, GMC Envoy, Oldsmobile Bravada, Isuzu Ascender, Saab 9-7X Will stop in 2010

GM. Wentzville Chevy Express, GMC Savana

GM. Lordstown Chevy Cobalt, Pontiac Pursuit, G4, G5

GM. Spring Hill Saturn Ion and Vue Currently down

GM. Doraville Chevy Uplander, Pontiac Montana

GM. Shreveport Chevy Colorado, GMC Canyon, Isuzu brands, Hummer H3

GM. Ramos Arizpe, Mex. Pontiac Aztek, Chevy Cavalier, Chevrolet Checy, Pontiac Sunfire, Buick Rendezvous

GM. Silao, Mex. Chevrolet Suburban, Chevrolet Avalanche, GMC Yukon, Cadillac Escalade

GM. Toluca, Mex. Chevrolet Kodiak Truck Stopping in 2008

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