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 • Toyota’s 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 Won’t 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
This note was uploaded on 01/09/2009 for the course ORIE 312 taught by Professor D.ruppert,p.jacks during the Spring '08 term at Cornell.
- Spring '08