The main topic of the case was the problems caused by defective or damaged seats. TMM USA's seat problem was threefold. The first was the actual defects with the hooks and the damaged caused by cross threading by employees when installing the seats. This problem led to the second problem, which was the departure from the Toyota Production System (TPS) when dealing with the seat problem. Rather than fix the problem with the seat when it happened, they continued with the car's production and worried about the seat afterwards. And this led to the third problem, a build up of cars with seat problems.
As manager of assembly, Doug Friesen should address the problem by focusing on this exception and reasons for allowing such a deviation from Toyota Motors Manufacturing (TMM) normal way of handling problems. He should also look at the communication and synchronization between Kentucky Framed Seat (KFS), the seat supplier, and the plant. One issue that he should look at is why these cars were sitting in the overflow lot... [continues]
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