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PPT : Toyota Motor Manufacturing (TMM) – A case on Just in time and Total Quality Management

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TOYOTA – the Largest Car Manufacture

History of the Plant
o Ground breaking, May 1986
o First Car, May 1988
o Fujio Cho named the second president, Dec 1988
o 1 millionth Camry, Oct 1993
o 2 millionth Camry, Apr 1997
o Camry #1 selling car in the US in 97, 98, 99, 00
o Gary Convis named fifth president, Apr 2001
o Camry #1 selling car in the US in 02, 03, 04, 05
o Sixth generation Camry starts, Feb 2006

Doug Friesen’s problem

Arun ratio of ??%: Number assembled actually / Number could be assembled
* Line is stopped due to defectives by pulling an andon cord
o Too often or too rare?
* ????, defective car-seat combinations sent downstream
* Defectives are due torotation, productdesign
* A substantial number of cars off-line with seats orseats.
o Some cars wait days for seats in thearea although commits to send seats in a single shift.
+ Is the reordering of Ex.9 form readable?
+ Cars served FIFO?
o What is the problem with the seats?

A Test of Japanese
* Ikko-nagashi: Lot size of one
* Heijunka: Production smoothing to end up with a level plan
* Jidoka: Do not pass the defects to downstream
* Takotei-mochi: Worker flexibility
* Tsukurikomi: Built-in quality inspection

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