systematically on the shop floor, as plants practicing JIT and Jidoka were prone to shutdowns • Toyota’s corporate slogan “ Good Thinking, Good Products” was enforced with senior manager coaching and internal trainings – Five Whys and Kaizen were proactively perused to continually develop the TPS
The Problem • Rise in number of Camry’s with defective seats, leading to reduced run ration at TMM Georgetown Plant in 1992 1992 Toyota Camry 1992 Toyota Camry Wagon
The Seat • Camry seats have 5 parts – Front right seat – Front left seat – Rear bench – Rear backrest – Rear Side bolsters • Seat- a very critical part – Soft part prone to damages-require special handling – Bulkiest of all parts – Related to cars crash performance – Prime customer touch point – Costliest of all purchased parts
Current Senario • Seat is supplied by Kentucky Framed Seats (KFS) who is the sole supplier • Operation mechanism- sequential pull • TMM is facing issues with seat supply for the Camry from 1992 • Major issues observed: – part quality issues – Missing child parts etc – Part not working • Reason for issue- product proliferation – Increased color and seat styles in Camry sedan, Introduction of Camry wagon & export models – Seat sets need to match the car in sequence – Sequential pull –(57 sec cycle time); minimal response time – Heijunka -more frequent changes in variation setup – Suppliers also operate under JIT.
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- Fall '16
- Toyota Production System, Toyota Motor Manufacturing, toyota production, Toyota Camry, Toyota Camry Wagon