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What is Productivity
Output/Input Increased Production with lesser input of assets- manpower, material
In 2002, Lexus outsold BMW, Cadillac and Mercedes Benz in the US for the third year in a row.
In 2003, sold more vehicles than Ford and Chevrolet.
The company has made profit every year over the last 25 years and has approximately $20-$30 billion in cash on a consistent basis.
More laurels
In 2003, Toyota recalled 79% fewer vehicles in US than Ford and 92% fewer than Chrysler. According to Consumer Reports, 15 out of the 38 most reliable models from any manufacturer over the last seven year came from Toyota/Lexus. According to J.D. Powers ranking for initial quality and long-term durability, Lexus was #1 most reliable car in 2003 followed by Porsche, BMW and Honda.
Not a single Toyota car is on the dreaded vehicles to avoid list published by Consumer Reports. About 50% of the GMs and more than 50% of the Chryslers are to be avoided.
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Toyota story
The mistake-proof loom became Toyodas most popular model and in 1929, his son Kichiro, negotiated the sale of patent rights to Platt Brothers of England for 100,000. In 1930, these funds were used to start building the Toyota Motor Corp. Kichiros contribution to the Toyota philosophy JIT. What is JIT? marriage between the Fords idea of assembly line and US supermarket system of replacing products on the shelves just in time as customer purchased them.
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Toyota story
Post-WWII, rampant inflation meant getting paid by customers was very difficult. Cash-flow problems lead to pay cuts. When situation worsened, 1600 workers were asked to retire voluntarily. The resultant work stoppages and public demonstrations by workers led to resignation of Kichiro. Eiji Toyoda took over as president. Eijis main contribution leadership towards development of the TPS. Eiji hired Taiichi Ohno as the plant manager and asked him to improve Toyotas manufacturing process so that it equals the productivity of Ford.
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Toyota story
Taiichi Ohno benchmarked the competition by visiting Ford and studied Henry Fords book. Impressed with Fords philosophy of eliminating waste. Ford itself didnt seem to practice it. Took idea of reducing inventory by implementing pull system from the US supermarkets. Pull system was implemented by Kanban cards. Ohno also took ideas from Deming when he was lecturing in Japan about quality and productivity.
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Toyota story
Deming told the Japanese industry about meeting and exceeding customer satisfaction. Also broadened the definition of customer to include both internal as well as external customers. The next process is the customer became the most significant expression for JIT, because in a pull system it means the proceeding process must always do what the subsequent process says. Otherwise JIT wont work.
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14 Toyota-Way Principles
Section I Long-term philosophy Principle 1: Base your management decisions on a long-term philosophy, even at the expense of short-term financial goals. Section II The Right processes will produce the right results Principle 2: Create continuous process flow to bring problem to the surface. Principle 3: Use pull system to avoid overproduction. Principle 4: Level out the workload (heijunka). (work like a tortoise not the hare.) Principle 5: Build the culture of stopping to fix problems to get quality right the first time.
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14 Toyota-Way Principles
Principle 6: Standardize tasks are the foundation for continuous improvement and employee empowerment. Principle 7: Use visual control so no problems are hidden. Principle 8: Use only reliable, thoroughly tested technology that serves your people and processes. Section III Add value to the organization by developing your people and partners Principle 9: Grow leaders who thoroughly understand the work, live the philosophy, and teach it to others.
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14 Toyota-Way Principles
Principle 10: Develop exceptional people and teams who follow your companys philosophy. Principle 11: Respect your extended network of partners and suppliers by challenging them and helping them improve.
Section IV Continuously solving root problem drives organizational learning Principle 12: Go and see for yourself to thoroughly understand the situation (genchi genbutsu). Principle 13: Make decisions slowly by consensus, thoroughly considering all options, implement decisions rapidly.
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14 Toyota-Way Principles
Principle 14: Become a learning organization through relentless reflection (hensei) and continuous improvement (kaizen).
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Types of waste
Overproduction: Producing items for which there are no orders, which generates such wastes as overstaffing and storage and transportation costs because of excess inventory. Waiting: Workers having to stand around waiting for the next processing step, tool, part etc. Or no work because of stockouts, lot processing delays, equipment downtime, and capacity bottlenecks. Unnecessary transport: Carrying WIP long distances, creating inefficient transport, or moving parts in and out of storage facility.
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Types of waste
Over-processing or incorrect processing: Taking unneeded steps to process the parts. Inefficient processing due to poor tools and product design, causing unnecessary motion and producing defects. Waste generated when providing higherquality products than is necessary. Excess inventory: Excess raw material, WIP or finished goods causing longer lead times, obsolescence, damaged goods. Extra inventory hides problems such as production imbalances, late deliveries from suppliers, defects, equipment downtime, and long set-ups. Unnecessary movements: Any wasted motion employees have to perform during the course of their work, such as looking for, reaching for, or stacking parts, tools etc. Walking is a waste.
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Types of waste
Defects: Production of defective parts or correction. Repair or rework, scrap, replacement production, and inspection mean wasteful handling, time and efforts. Unused employee creativity: Losing ideas, skills, improvements, and learning opportunities by not engaging or listening to your employees.
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Eliminating Waste
First step in removing non-value added steps from a process is to map the process. Map the value stream following the actual path taken by the part in the plant. Walk the full path yourself One can draw the path on a layout and calculate the time and distances traveled (spaghetti diagram). Traditional cost saving focuses on value-added items and try to improve those. TPS focuses on the entire value stream to eliminate the nonvalue adding items.
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Kanban system
At Toyota, empty bin (a kanban) is send upstream after a demand instance. It is a signal to refill it with a specific number of parts or send back a card with detailed information about the part location. Even today, one can see Kanban cards and bins moving on the shop-floor. Instead of using sophisticated computer scheduling techniques, this is a simple, effective and visual system of managing and ensuring the product flow and JIT production system.
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Kanban system
Gas tank example. Toyota philosophy about kanban: Kanban is an organized system of inventory buffers and as per TPS, inventory is waste, whether it is in pull system or push system. So kanban is something you strive to get rid of. Toyota uses kanban to force process improvements.
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Kanban system
Suppose we have four kanban cards for a particular products. One each for four bins of products. TPS will conduct studies in which one of the kanban cards (along with the corresponding bin) is thrown away. Now, if the machine breaks down, the downstream process will run out of parts 25% faster. The stress in the system will cause production shutdowns, and will force teams to come up with process improvements.
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Jidoka- Autonomation
Hence we need a method to detect defects when they occur and automatically stop production so an employee can fix the problem before the defect continues downstream. Jidoka is also referred to as autonomation equipment endowed with human intelligence to stop itself when it has a problem. In-station quality is much more effective and less costly than inspecting and repairing quality problem after the fact. Lean manufacturing dramatically increases the importance of building things right the first time. With very low levels of inventory, there is little buffer to fall back on in case there is quality problem.
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Barriers to Implementation
Early abandonment Costs History of conflict and distrust Resistance of supervisors Lack of supportive infrastructure
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How?
Use Toyota Methods
Proper Monitoring of all Systems Expected savings of Rs 15-20 Crore in DLW which is 1% of our Total Budget
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Questions?
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