Toyota Production System and Lean Manufacturing

Toyota Production System and Lean Manufacturing free pdf ebook was written by Leon on November 26, 2002 consist of 17 page(s). The pdf file is provided by etidweb.tamu.edu and available on pdfpedia since April 23, 2012.

toyota production system and lean manufacturing d. jorge leon texas a&m university toyota production..system) quality control: autonomation, improvement by small groups, functional management respect for humanity : flexible..involvement by all employees • successful implementation requires that all employees must...

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Toyota Production System and Lean Manufacturing pdf




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Toyota Production System and Lean Manufacturing - page 1
Toyota Production System and Lean Manufacturing D. Jorge Leon Texas A&M University TOYOTA PRODUCTION SYSTEM The Toyota Production System was adopted by many Japanese companies in the aftermath of the 1973 oil shock “Waste” Elimination Philosophy: “.. Above all, one of our most important purposes was increased productivity and reduced cost. To achieve this purpose, we put our emphasis on the notion of eliminating all kinds of unnecessary functions in the factories. Our approach has been to investigate one by one the causes of various "unnecessaries" in manufacturing operations and to devise methods for their solution, often by trial and error ...” Taiicho Ohno, Former Vice President, Toyota Motor Corp., Former President, Japan Industrial Management Association; Former Chairman, Toyoda Spinning and Weaving Co., Ltd. 1
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Toyota Production System and Lean Manufacturing - page 2
PURPOSES OF JIT Primary Purpose: Profit through cost reduction (or improvement of Productivity) This is attained through WASTE elimination. Other important purposes: Quantity control: JIT, Kanban & Autonomation (visual control system) Quality control: Autonomation, improvement by small groups, functional management Respect for humanity : Flexible work force (adapt to demand changes), capitalize workers ideas. TYPES OF WASTE Excessive production resources (primary waste): excessive workforce excessive facilities excessive inventories unnecessary capital investment Overproduction (secondary waste - the WORST waste): leads to Excessive inventories (tertiary waste): extra jobs make overproduction invisible. adds losses in opportunity cost lead to Unnecessary capital investment (fourth waste): adds facility depreciations and overhead cost 2
Toyota Production System and Lean Manufacturing - page 3
TO ACHIEVE THESE PUPOSES 7 Wastes Elimination Just-In-Time (JIT) Production Kanban System Production Smoothing 5S Setup Time Reduction Machine Layout & Multi-function Worker Autonomation (Visual Management) 3
Toyota Production System and Lean Manufacturing - page 4
7 Wastes, Applied Material’s, Lean Manufcaturing, Supplier Copy, 1999. 7 Wastes, Applied Material’s, Lean Manufcaturing, Supplier Copy, 1999. Identification and Elimination of Waste Philosophy Identification and elimination of waste is the central theme of a lean manufacturing production system Lean manufacturing is a dynamic and constantly improving process dependent upon understanding and involvement by all employees Successful implementation requires that all employees must be trained to identify and eliminate waste from their work Waste exists in all work and at all levels in the organization 4
Toyota Production System and Lean Manufacturing - page 5
7 Wastes, Applied Material’s, Lean Manufcaturing, Supplier Copy, 1999. 7 Wastes, Applied Material’s, Lean Manufcaturing, Supplier Copy, 1999. Identification and Elimination of Waste Philosophy Effectiveness is the result of the integration of: - Man - Method - Material - Machine At the worksite Waste exists in all work and at all levels in the organization 7 Wastes, Applied Material’s, Lean Manufcaturing, Supplier Copy, 1999. 7 Wastes, Applied Material’s, Lean Manufcaturing, Supplier Copy, 1999. Seven Types of Waste Over-production Wait time Transportation Processing Inventory Motion Defects 5
Toyota Production System and Lean Manufacturing - page 6
7 Wastes, Applied Material’s, Lean Manufcaturing, Supplier Copy, 1999. 7 Wastes, Applied Material’s, Lean Manufcaturing, Supplier Copy, 1999. Over-production Waste Definition Producing more than needed Producing faster than needed 7 Wastes, Applied Material’s, Lean Manufcaturing, Supplier Copy, 1999. 7 Wastes, Applied Material’s, Lean Manufcaturing, Supplier Copy, 1999. Over-production Waste Characteristics: Inventory Stockpiles Extra equipment/oversized equipment Unbalanced Material Flow Extra Part Storage racks Extra Manpower Batch Processing Complex Inventory Management Excessive Capacity/Investment Additional Floor Space/Outside Storage Hidden Problems Excessive Obsolescence Large Lot Sizes Building Ahead 6
Toyota Production System and Lean Manufacturing - page 7
7 Wastes, Applied Material’s, Lean Manufcaturing, Supplier Copy, 1999. 7 Wastes, Applied Material’s, Lean Manufcaturing, Supplier Copy, 1999. Over-production Waste Causes: Incapable Processes Just in Case Reward System Lack of Communication Local Optimization Automation in the Wrong Places Cost Accounting Practices Low Uptimes Lack of Stable/Consitent Schedules 7 Wastes, Applied Material’s, Lean Manufcaturing, Supplier Copy, 1999. 7 Wastes, Applied Material’s, Lean Manufcaturing, Supplier Copy, 1999. Waiting Time Waste Definition Idle Time That is Produced When Two Dependant Variables are not Fully Synchronized. Man Wait Time Machine Wait Time 7
Toyota Production System and Lean Manufacturing - page 8
7 Wastes, Applied Material’s, Lean Manufcaturing, Supplier Copy, 1999. 7 Wastes, Applied Material’s, Lean Manufcaturing, Supplier Copy, 1999. Waiting Time Waste Characteristics: Man Waiting for Machine Machine/Materials Waiting for Man Unbalanced Operations (Work) Lack of Operator Concern for Equipment Breakdowns Unplanned Equipment Downtime 7 Wastes, Applied Material’s, Lean Manufcaturing, Supplier Copy, 1999. 7 Wastes, Applied Material’s, Lean Manufcaturing, Supplier Copy, 1999. Waiting Time Waste Causes: Inconsistent Work Methods Long Machine Change Over Time Low Man/Machine Effectiveness Lack of Proper Equipment/Materials 8
Toyota Production System and Lean Manufacturing - page 9
7 Wastes, Applied Material’s, Lean Manufcaturing, Supplier Copy, 1999. 7 Wastes, Applied Material’s, Lean Manufcaturing, Supplier Copy, 1999. Transportation Waste Definition Any Material Movement That Does Not Directly Support a Lean Manufacturing System 7 Wastes, Applied Material’s, Lean Manufcaturing, Supplier Copy, 1999. 7 Wastes, Applied Material’s, Lean Manufcaturing, Supplier Copy, 1999. Transportation Waste Characteristics: Extra carts, fork lifts, dollies Multiple Storage Locations Extra Material Racks Complex Inventory Management Extra Facility Space Incorrect Inventory Counts Damaged Material 9
Toyota Production System and Lean Manufacturing - page 10
7 Wastes, Applied Material’s, Lean Manufcaturing, Supplier Copy, 1999. 7 Wastes, Applied Material’s, Lean Manufcaturing, Supplier Copy, 1999. Transportation Waste Causes: Large Lot Processing Unleveled Schedules Lack of 5 S’s Lack of Visual Controls Improper Facility Layout Large Buffers and In Process Kanbans 7 Wastes, Applied Material’s, Lean Manufcaturing, Supplier Copy, 1999. 7 Wastes, Applied Material’s, Lean Manufcaturing, Supplier Copy, 1999. Processing Waste Definition Effort Which Adds No Value To a Product or Service. Enhancements which are Transparent to The Customers or Work Which Could Be Combined with Another Process. 10
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