This preview shows pages 1–3. Sign up to view the full content.
This preview has intentionally blurred sections. Sign up to view the full version.View Full Document
Unformatted text preview: The Toyota Production System Peter L. Jackson School of Operations Research and Information Engineering Cornell University Adapted from: Black, J.T. 1991. The Design of the Factory With a Future. McGraw-Hill, Inc. ISBN 0-07-005550-5 2/19/2007 Industrial Data and Systems Analysis 2 A Rose By Any Other Name... The Toyota Production System Toyotas VP of Manufacturing: Taiichi Ohno The Ohno System many companies in Japan JIT/TQC (just-in-time/total quality control) many companies Stockless Production Hewlett Packard Synchronous Manufacturing GM 2/19/2007 Industrial Data and Systems Analysis 3 A Rose By Any Other Name... MAN (material as needed) Harley Davidson ZIPS (zero inventory production system) Omark Industries MIPS (minimum inventory production system) Westinghouse Continuous Flow Manufacturing IBM 2/19/2007 Industrial Data and Systems Analysis 4 What J.T. Black Calls It Integrated Manufacturing Production System (IMPS) Then, if computers are used, Computer-Integrated Manufacturing Production System (CIMPS) 2/19/2007 Industrial Data and Systems Analysis 5 Why It Wont Work Here We tried that once. Management would never accept it. The union would never accept it. Our culture is too different. Our business is too complicated. Our systems are too complex. 2/19/2007 Industrial Data and Systems Analysis 6 Where It Has Worked Shipbuilding Industrial machinery Apparel Machine tools Drugs Motorcycles Electrical and electronics Automobiles Steel products Steel 2/19/2007 Industrial Data and Systems Analysis 7 Fundamental Concepts: Respect People Change management attitudes everyone is called an associate eliminate executive privileges Manage by consensus Increase responsibility Reward achievement of goals change compensation scheme Use automation/robotics to solve problems not to eliminate direct labor cost Engage the supplier eliminate adversarial relationships 2/19/2007 Industrial Data and Systems Analysis 8 Fundamental Concepts: Eliminate Waste Focus factories (organize cells) Eliminate overproduction Manufacture just-in-time (produce in small lots) Eliminate or reduce setup time Eliminate defects Eliminate equipment downtime Eliminate or reduce inventory Eliminate or reduce indirect labor Conserve space J0 Steps to Implement CIMPS (J.T. Black: 10 Steps to IMPS ) J1 Cellularize J2 Link J3 Automate Self-directed, customer-focused teams of multi- functional workers in flexible production cells Demand-pulled production systems integrated with qualified suppliers Computer- integrated manufacturing production systems Manned cells Integrated manufacturing production systems producing low-cost, superior quality products with on-time delivery J1 Cellularize J11 Form Cells J13 Integrate Quality Control...
View Full Document
- Spring '08