Toyota Production System.pptVIP

2.810 T.G.Gutowski 10/29/01 The Toyota Production System High Quality and Low Cost Readings; James Womack, Daniel T. Jones and Daniel Roos, The Machine that Changed the World, 1990, Ch 3 and 4 Kenneth N. McKay, “The Evolution of Manufacturing Control- What Has Been, What Will Be” Working Paper 03 –2001 Michael McCoby, “Is There a Best Way to Build a Car?” HBR Nov-Dec 1997 Consumer Reports The Toyota Production System Historical View Performance measures Elements of TPS Six Eras of Manufacturing Practice Difficulties with Implementation Three Major Mfg Systems from 1800 to 2000 Key Elements for New Mfg Systems Q. By what method did these new systems come about? A. Trail and Error History of the Development of the Toyota Production System ref; Taiichi Ohno The Toyota Production System Historical View Performance measures Elements of TPS Six Eras of Manufacturing Practice Difficulties with Implementation Summary 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 Roos The Toyota Production System Historical View Performance measures Elements of TPS Six Eras of Manufacturing Practice Difficulties with Implementation How do you get this kind of performance? Womack, Jones and Roos J T. Black’s 10 Steps Demand Flow Technology’s 9 Points MSDD, D. Cochran and Students Womack Jones and Roos Automation? Yes, but…. DFM? Probably Standardized Production? No! Lean Characteristics? Integration of Tasks Identification and removal of defects Cost Vs AutomationRef. “Machine that Changed the World” Womack, Jones and Roos J T. Black’s 10 StepsRef; JT. Black “Factory with a Future” 1991 1. Form cells 2. Reduce setup 3. Integrate quality control 4. Integrate preventive maintenance 5. Level and balance 6. Link cells – KANBAN 7. Reduce WIP 8. Build vendor programs 9. Automate 10. Computerize Demand Flow Technology’s  9 Points