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PPT : Quality Assurance Team Toyota

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The Toyota Production System

* Unique production system
o Allows for continuous quality improvement
o Rated best vehicle in all categories for quality by JD Power
* GM, Chrysler, and Ford have tried to develop Toyota like production systems
* Scientific method is ingrained in Toyota’s production process
* Teaches the scientific method to all levels of the organization
* The four rules guide design, operation, and improvement for every product
o Rule 1: Scope shall be clearly defined
o Rule 2: Every customer-supplier connection must be direct and unambiguous
o Rule 3: The pathway for every product and service must be simple and direct
o Rule 4: All improvements must be made in accordance with the scientific method

* All work shall be highly specified
* Scope is clearly defined
o Case study: seat installation
+ Bolts are always tightened in the same order
+ Time taken to turn each bolt is specified
+ Torque of each bolt is specific value

* Every customer-supplier connection must be direct
o Case study: seat installation
+ Acquisition of seat bolt covers by installer
+ Request is given to materials handler
+ Request specifies part number, quantity of parts, location of part supplier, and location of the installer
+ Coordinated materials handling prevents time lost in production

* The pathway for every product and service must be simple and direct
o Case study: seat installation
+ Seat installer requests more plastic bolts covers
+ No forks or loops in supply chain
+ Installer – materials handler – designated supplier
+ Goods flow from to specific person or machine

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