The Toyota Production SystemConsumer ReportsPowerPoint PresentationSlide 4Three Major Mfg Systems from 1800 to 2000Key Elements for New Mfg SystemsQ. By what method did these new systems come about?History of the Development of the Toyota Production System ref; Taiichi OhnoSlide 9Summary of Assembly Plant Characteristics, Volume Producers, 1989 (Average for Plants in Each Region)Cost Vs Defects Ref. “Machine that Changed the World” Womack, Jones and RoosSlide 12How do you get this kind of performance?Womack Jones and RoosCost Vs Automation Ref. “Machine that Changed the World” Womack, Jones and RoosJ T. Black’s 10 Steps Ref; JT. Black “Factory with a Future” 1991Demand Flow Technology’s 9 PointsCurrent Value Stream MapFuture Value Stream MapManufacturing System Design Decomposition (MSDD)J T. Black –1, 2TPS CellStandardized FixturesJ T. Black – 3, 4J T. Black – 5, 6J T. Black – 7, 8Slide 27Example from Cochran – Minimize production disruptionsSome Basics Concepts of TPSTwo Examples;Takt Time – to pace productionTakt TimeEngines shipped over a 3 month period at aircraft engine factory “B”Engines shipped over a 3 month period at aircraft engine factory “C”On-time performance of engine plantsPush and Pull SystemsPush Systems – Order arrives at the front of the system and is produced in the economical order quantity. Q. How long did it take for the order to go through the system?Pull Systems- The order arrives at the end of the line and is “pulled” out of the system. WIP between the machines allows quick completion.Comparison in delivery timesHP Video ResultsHP Video Results RevisitedSo what are the advantages of the pull systems?Slide 43Six Eras of Manufacturing Practice, Ken McKayKen McKay – 1, 2Ken McKay – 3, 4Ken McKay- 5, 6Slide 48TPS ImplementationWork practices and people issuesExamples of “Innovative” Work Practices“What Works at Work: Overview and Assessment”,Slide 53Slide 54Slide 55Barriers to ImplementationSummarySummary …….. continued2.810 T.G.Gutowski 10/29/01 1The Toyota Production SystemHigh Quality and Low CostReadings; James Womack, Daniel T. Jones and Daniel Roos, The Machine that Changed the World, 1990, Ch 3 and 4Kenneth N. McKay, “The Evolution of Manufacturing Control-What Has Been, What Will Be” Working Paper 03 –2001Michael McCoby, “Is There a Best Way to Build a Car?”HBR Nov-Dec 1997COST VS DEFECTS2.810 T.G.Gutowski 10/29/01 2Consumer Reports2.810 T.G.Gutowski 10/29/01 3Septem ber January - Septem berUnits % Share DSR VolCurrent Year-Ago Current Year-Ago % Chg. Current Year-Ago % Chg.Domestic Cars431,496 481,318 35.3 37.3 -2.6 4,594,203 4,865,569 -5.6Import Cars170,554 158,897 13.9 12.3 16.7 1,708,780 1,566,286 9.1Total Cars602,050 640,215 49.2 49.7 2.2 6,302,983 6,431,855 -2.0Domestic Light Trucks545,865 573,329 44.6 44.5 3.5 5,769,260 5,621,805 2.6Import Light Trucks75,999 75,575 6.2 5.9 9.3 798,656 711,178 12.3Total Light Trucks621,864 648,904 50.8 50.3 4.2 6,567,916 6,332,983 3.7Domestic Light Vehicles977,361 1,054,647 79.9 81.8 0.7 10,363,463 10,487,374 -1.2Import Light Vehicles246,553 234,472 20.1 18.2 14.3 2,507,436 2,277,464 10.1Total Light Vehicles1,223,914 1,289,119 100.0 100.0 3.2 12,870,899 12,764,838 0.8Ward's U.S. Light Vehicle Sales SummaryToyota vehicle sales20022.810 T.G.Gutowski 10/29/01 4The Toyota Production System1. Historical View 2. Performance measures 3. Elements of TPS4. Six Eras of Manufacturing Practice5. Difficulties with Implementation2.810 T.G.Gutowski 10/29/01 5Three Major Mfg Systems from 1800 to 20001800 1900 2000Machine tools, specialized machine tools, Taylorism, SPC, CNC, CAD/CAM Interchangeable Parts at U.S. ArmoriesMass Production at FordToyota Production System2.810 T.G.Gutowski 10/29/01 6Key Elements for New Mfg SystemsElement/SystemNeed of SocietyWork Force MotivationEnabling TechnologyLeader ResourcesInterchange-able PartsMilitary “Yankee Ingenuity”Machine Tools, Division ofLaborRoswell Lee/JohnHallU.S.GovtMassProductionTrans-portation$5/dayImmigrantMovingAssemblyLine,etcHenryFordEarningsToyota Production SystemPost WarJobs,SecurityCNC, Integration of LaborTaiichiOhnoJapaneseBanks2.810 T.G.Gutowski 10/29/01 7Q. By what method did these new systems come about?A. Trail and Error2.810 T.G.Gutowski 10/29/01 8History of the Development of the Toyota Production System ref; Taiichi Ohno194519752.810 T.G.Gutowski 10/29/01 9The Toyota Production System1. Historical View 2. Performance measures 3. Elements of TPS4. Six Eras of Manufacturing Practice5. Difficulties with Implementation2.810 T.G.Gutowski 10/29/01 10Japanese Japanese in American in All Europein Japan North America North AmericaPerformanc e:Produc vitity (hours/Veh.) 16.8 21.2 25.1 36.2Quality (assemblydefec ts/100 vehic les) 60 65 82.3 97Layout:S pace (sq.ft./vehic le/yr) 5.7 9.1 7.8 7.8S iz e of Repair Area (as %of assembly space) 4.1 4.9 12.9 14.4Inventories(days for 8sample parts) 0.2 1.6 2.9 2Work Force:% of Work Forc e in Teams 69.3 71.3 17.3 0.6Job Rotation (0 = none,4 = frequent) 3 2.7 0.9 1.9S uggestions/Employee 61.6 1.4 0.4 0.4Number of Job Classes 11.9 8.7 67.1 14.8Training of New Produc tionWorkers (hours) 380.3 370 46.4 173.3Absenteeism 5 4.8 11.7 12.1Automation:Welding (% of direc t steps) 86.2 85 76.2 76.6Painting(% of direc t steps) 54.6 40.7 33.6 38.2Assembly(% of direct steps) 1.7 1.1 1.2 3.1S ource: IMVP World Assembly Plant S urvey, 1989, and J. D. Power Initial Quality S urvery, 1989Summary of Assembly Plant Characteristics, Volume Producers, 1989 (Average for Plants in Each Region)2.810 T.G.Gutowski 10/29/01 11Cost Vs Defects Ref. “Machine that Changed the World” Womack, Jones and Roos2.810 T.G.Gutowski 10/29/01 12The Toyota Production System1. Historical View 2. Performance measures 3. Elements of TPS4. Six Eras of Manufacturing Practice5. Difficulties with Implementation2.810 T.G.Gutowski 10/29/01 13How do you get this kind of performance?1. Womack, Jones and Roos2. J T. Black’s 10 Steps3. Demand Flow Technology’s 9 Points4. MSDD, D. Cochran and Students2.810 T.G.Gutowski 10/29/01 14Womack Jones and RoosAutomation? Yes, but….DFM? ProbablyStandardized Production? No!Lean Characteristics? Integration of TasksIdentification and removal of defects2.810 T.G.Gutowski 10/29/01 15Cost Vs AutomationRef. “Machine that Changed the World” Womack, Jones and Roos2.810 T.G.Gutowski 10/29/01 16J T. Black’s
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