Session 8 Toyota Production System

Session 8 Toyota Production System - OSCM356 Operations...

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1 OSCM356 Operations Management Session 8 Toyota Production System Fuqiang Zhang Olin Business School Washington University in St. Louis Spring 2008 Session outline Toyota Production System Just-in-Time Jidoka Toyota Motor Manufacturing Case Problem identification Alternative solutions OSCM356, Spring 08, Prof. Zhang Session 8 Slide 2
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2 Why Toyota? OSCM356, Spring 08, Prof. Zhang Session 8 Slide 3 Toyota is now the world’s largest carmaker: Toyota sold 2.35 million vehicles in the first three months of 2007 while the number was 2.26 during the same period. – BBC News, April 24, 2007 History of Toyota OSCM356, Spring 08, Prof. Zhang Session 8 Slide 4 Early 1900s: Sakichi Toyoda started Toyota as a textile machine company 1930s: Kiichiro Toyoda developed the concept of Just-in-Time Post WWII: Taiichi Ohno developed Toyota Production System (TPS) 1990: The book The Machine That Changed the World: The Story of Lean Production was published 1990s: MIT researchers coined the term lean production to indicate this radically different approach to production 1970s: Toyota Production System (TPS) drew wide attention from the industrial community
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3 Toyota Production System (TPS) Definition : The production system developed by Toyota Motor Corporation to provide best quality, lowest cost, and shortest lead time through the elimination of waste. TPS is comprised of two pillars, Just-in-Time and Jidoka (autonomation). OSCM356, Spring 08, Prof. Zhang Session 8 Slide 5 House of Toyota OSCM356, Spring 08, Prof. Zhang Session 8 Slide 6 Goal: Highest Quality, Lowest Costs, Shortest Lead Time Just-in-Time Jidoka Heijunka Value Stream Mapping Kaizen Continuous Flow Pull System Kanban Quality at Source Poka-yoke Andon
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4 Just-in-Time Attacks waste Anything not adding value to the product Including over-production, wait time, inventory and defects… Achieves streamlined production By reducing inventory Exposes problems and bottleneck caused by variability OSCM356, Spring 08, Prof. Zhang Session 8 Slide 7 Continuous Flow Producing and moving one item at a time (or a small and
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Session 8 Toyota Production System - OSCM356 Operations...

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