Toyota Production System

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Research Operations Assignment

Course Details: Topic : Lecturer's: Prepared By: Student ID: Date:

BMO6508 - Operations Management Logistics Operations Plan for Toyota Boshoku Australia Chris Taylor and Dr.Nick Billington Adeel Ahmed s3621301 6/08/11

What kind of operations are done in LCD?
Parts receipt and delivery Receiving Parts Order parts Checking and Putting away parts in stores or warehouses Delivering parts to the production lines Picking empty boxes and bins from production areas Loading them onto trucks Ensuring trucks depart on time Subassembly of parts and sequencing Receive parts from production areas Assemble to the required standard Pick other parts needed to be sequenced Load onto trolleys or AGV's

within the required takt time available

The above LCD operations can be divided into 2 categories 1.Takt based jobs - jobs which need to be done within a fixed time which is decided by the volumes 2. Cyclic jobs - jobs which repeat in nature at a certain frequency or interval

TAKT based jobs
What is takt time? - Rate at which we need to produce = Time available / volume needed For eg.: If customers requirement is 570 cars per day 457 mins x 2 shifts x 60 secs TT = 570 = 96 sec @ 100% efficiency at 95% = 96x0.95 = 91sec

This means every position on the production line has 91 secs to complete the tasks for that position How do we decide what work each position does? The drawings for all the assemblies give us the information needed which helps in listing the sequence of operations. There are some operations which cannot be done unless the previous operation is done whilst there are some which may be possible.

In TPS the task of deciding what is to be done by each position and how much time the operator has is

visualised by a graph called the YAMAZUMI - 'yama' in japanese mean mountain and 'zumi' means putting on top of each other. There are 3 tools which are used to prepare the yamazumi charts The standard work sheet The combination chart The process capacity sheet - used when we need to determine machine capacities and process outputs The standard work sheet is the fundamental document which lists all the tasks the operator needs to do This must be diligently followed and checked by supervision (TL, GL) It is only when this is done that we can identify normal and abnormal operations and identify opportunities to Improve. The combination chart is a detailed graph identifying the basic elements (manual work, automatic, walking and waiting). By plotting this graph we can identify elements which are non- value adding and provide the trigger needed to try to think about minimising them. The process sheet helps in identifying the machine cycle times and the process times which help in determining the output from each line. How to use the above tools and plot the yamazumi for TT based jobs? Using the standard work chart and the timings for each element of the work being done a graph is plotted. The work content for each type of product being produced at that position may be different Since the volume for each product being manufactured is different we cannot use just average as the allowable time. This will result in excessive waste of time

Hence for each position we calculate the weighted average. The weighted average takes into account the ratio of the volume for each type of product For eg: If our daily volume is 570 per day and we have 3 types of products, the quantities of which are 342 (60%), 2 is 171(30%) and 3 is 57 (10%) and if the time taken at position 1 for type1 is 88secs, for type2 is 92 secs and type 3 is 100 secs. then the weighted average is ((88x342)+(92x171)+(57x100))/570 = 90.4 POSITION 1 1comfort 60% 342 88 2 sport 30% 171 92 3 luxury 10% 57 100 90.4 91 Wtd. Avg. TT 91" T

Time taken at position 1 for the activities to be done for the 3 different types

1 2 3


How do we improve the productivity in takt based jobs?

Productivity improvements are measured...
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