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Toyota Seat Problem Case Summary

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Toyota Seat Problem Case Summary

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CAUSES OF OVERLOAD AT THE KENTUCKY PLANT:
overload as production for North Amercia and European markets was also being handled. line utilisation rate was below the projected target
compensation for time lost over defective or no seats

URGENCY TO HANDLE THE SEAT PROBLEM:
trying to solve the seat problem could hurt the line utilisation

BACKGROUND:
Japan wanted to set up a plant in North America due to mounting political pressure and rapidly rising yen. However, the plant set up in Kentucky by Toyota Motor Corporation (TMC) in 1985 proved to be a hindrance. So there was a big challenge faced by Japan to set up shop in AMerica.

In 1988, Toyota Motor Manufacturing set up shop in Georgetown to increase volume to counter theimports of cars from Japan and sold the cars at cheaper prices. The car captured market shares.

Toyota strive
making quality cars at affordable prices for a diverse range of customers.

Toyota Production System:
Aimed at cost reduction by eliminating waste.
Factors explaining why waste reduces productivity and quality.

Identification of factors caussing waste:
JIT & jidoka

jidoka - necessitated standardisation of the process
Importance of a good workforce
kaizen - change for the better

Georgetown Ramp up:
Simulate model in Japan
Get people from Japan who knew the process and how to handle the situations.

OPERATIONS:

Assembly:
line cycle time ?
provision to demarcate various items in the assembly line so that everything was clearly visible. Also, precautions were taken so that if 'x' amount was not completed in the stipulated time the andoncord was pulled which gathered the attention of the team leader.

Production control:
its duty is to provide the right parts to TMM at the right time so that the right cars can be produced. heijunka - facilitated JIT - evenedd out production
kanban - facilitated JIT - signalled manufacture of part to the supplier

Quality Control:
work in sync with the assemble...