Transcript Facility Layout - Management Class

Lean Production
Toyota Motor Manufacturing (TMM)
Mass Production System
Toyota Production System (TPS)
Linkage between production control and quality
Costs of poor quality & supplier management
What Did Toyota do Differently?
Complexity combined with variability makes
operations very difficult to manage efficiently.
Deterministic Variability
Randomness
Variability
Operational
Complexity
More
Difficult
to
Manage
Potential
Inefficiency
Toyota has become the world’s preeminent
manufacturer by systematically attacking these two
causes at the root level.
A Short History of
Production Systems

Craft Production
– Complete customization, MTO
– Work stationary, people move
– Skilled crafts, especially joiners

Mass Production (Henry Ford)
– Standardized Gauges
– Standardized product (at first) MTS
• Later as many options as possible
– Work moves, people stationary
– Simplified, easy-to-understand tasks
– Unskilled workers
– Quality control by specialists. if any
– Massive buffers
– Vertical Integration

But then came Taiichi Ohno &
Shigeo Shingo
Toyota Production System (TPS)
What are the precepts of the Toyota
Production System (TPS)?

Eliminate waste

Good thinking by everybody

Production leveling (Heijunka)

Marry your supplier (Keiretsu)
TPS at TMM

What are some examples of TPS at
Georgetown?
JIT at Georgetown
SIMPLIFIED PROCESS FLOW DIAGRAM
Half-hour
Buffer
shells
OTHER
OPERATIONS
PAINT
EDI
FINAL
ASSY
SEATS
(>58)
100%
INSPECTION
SEAT
ASSY
FGI
(58)
TRANSPORT
(30 MINS)
Batch Size = 1
Cycle Time for both is 57 secs
The Problem at TMM
What are the basic issues at TMM?
What are the important trends?
Finding the Solution
TMM faces an incredibly difficult tradeoff:
short-term costs
long-term costs
Potential Solutions
What are some pragmatic solutions to the seat
problem that don’t break TPS?
The Message

Toyota has very similar production
principles to Benihana
–
–
–
–
–
–
Limited Menu
Minimize Flowtime
Minimize Waste
Minimize Inventory
Minimize Space
Highly Motivated & Trained Workforce

But with one crucial difference

Food for thought: Is Lean or
Synchronous (The Goal) production
better?