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Toyota manufacturing case study
Strength and weakness of the Toyota production system
Strength and weakness of the Toyota production system
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MANAGEMENT AND ORGANISATIONAL ANALYSIS ASSIGNMENT (QUESTION 2)
12J01DMBA024
AFRICA NAZARENE UNIVERSITY
PRESENTED TO DR KABARE The term Lean production is always associated with the term Toyota Production System which dates back to the 1940s. Toyota Production System was the result of studies and subsequent management tools developed by a team that was looking for ways to meet the productivity challenges that Toyota faced when the company first entered the automotive manufacturing industry.
Lean manufacturing is a system that integrates the routine work of producing and delivering services and information with problem identification and process improvement to eliminate waste and reduce production lot sizes. Lean production has emerged
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These are explained below:
1. Cost Minimization Stocks are costly to store, move and maintain. By implementing lean production, an organization is able to minimize its stock quantities in its production processes thereby reducing stock associated costs to achieve a better bottom-line.
2. Improved Customer Satisfaction
One of the key principles of lean is identifying value as perceived by the customer. If a manufacturer is always supplying top quality products and services on time, then this will lead to greater customer satisfaction. Lean production enables an organization keep in touch with their customer needs through research and it is therefore able to produce what the customers actually need.
3. Improved Quality
Lean production advocates for continuous improvement. This leads to improved product and service quality. By embracing lean, organizations keep abreast with technology in an attempt to improve the quality of their products. Organizations can stagnate without change and are soon phased out of competition. Lean production enables an organization to be forward looking and open to
Achieving quality of conformance involved conform to specifications that involve providing customers with a quality product at the right price which accounts for the cost of materials. In order for a company to achieve and produce a successful product that customers want and need, it is vital that quality management and lean systems play front row. Quality management helps organizations to reduce waste and inventory. “Lean is about challenging the way things are done and opening our eyes to that waste and inefficiency” (Lean Benefits - Benefits of Lean, Why Lean is Important, 2015). Within each of these concepts are important tool and techniques that organizations can use to achieve a quality product. In this paper I will discuss “cost of quality” from the quality management side and “kaizen’s” from the lean system side, while discussing how each of these concepts are implemented into my own life or
The company that the author has chosen to compare his own organization with is the Toyota motor company. The Toyota Company has become a renowned leader in the area of quality management. Toyota’s theory of “keep it lean” has kept the company running at a level that eclipses the industry standards.
We encourage the development and application of innovations, best practices, Lean tools and techniques. In order to grow the capabilities of our workforce we provide bespoke training and support through commitment. As a result the company maintains a market head position and benefits from a fully engaged and satisfied workforce.
Lean Six Sigma is a methodology that creates processes within an organization to cut waste and improve the company’s performance. However, studies have shown that over the past decade applying Lean Manufacturing and Six Sigma can create problems for companies financially and potential problems for employees. Companies should take great care before implementing a Lean Six Sigma solution because in some instances, going lean can do more harm than good both financially for the organization as well as destroying employee loyalty and moral.
According to Christopher and Towill (2001), there are mainly three ways to combine lean and leagile. The first hybrid approach is the Pareto rule, which means that the dominant 20% of products should use leanness and make to stock. While the remaining 80% products with less share of revenue should use agility. The second hybrid approach is about using lean approach for the base level of demand, while for the peak season or flexible demand, manufacturer can use agility
Lean manufacturing refers to systematic identification and elimination of waste through CI processes in pursuit of perfection (Khan et al. 2013; Yang & Yang 2013). Lean production is now used worldwide in manufacturing plants to eliminate waste from all ar...
For organizations who have committed to invest and deploy quality systems improvement programs, it is a huge task for every member who is a part of the transformation. The benefits are felt once completed and outweigh the cost from a long-term standpoint. Col. Larsen offers a compelling argument that Lean principles, when properly applied, also result in significant improvement and transcends industry boundaries. Leadership from all levels must challenge traditional approaches, communicate, and execute as a team to design and obtain excellence in governance of safety.
Eastman Kodak has realized savings in the millions in transportation and inventory costs by implementing lean logistics. Kodak starting developing lean logistics in 2002 by establishing a cross docks to improve the flow of materials moving from its suppliers to its warehouses. Kodak picked three of its closes suppliers to try the lean logistics out. One main truck would go around to the suppliers and pick up supplies every two days and bring it back to the cross dock where it would be moved to the correct department. This one act has led to a $20 million inventory cost reduction because there is nothing being stored, and the shipping costs are low because they use their own trucks.
During this project, I am going to mention the details of TOYOTA production process system which was developed more than 40 years ago by Taiichi Ohno, the president of Toyota Motor company at that time. The production system that Toyota company uses now and before is relevant to the concept of the process costing system which is currently used in all department of the company.
Toyota is a pioneer of the LEAN manufacturing principle. Lean, as a process, is a way to add value to customers while minimizing waste (LEI, 2011). It can also be thought of in terms of flow, which is how Toyota likes to think of it. It is simply a process of decision making where the problems tend to be thought of in terms of flow, reducing starts and stops or unnecessary motion increases flow, reducing waste.
Lean manufacturing and just-in-time processing are great business strategies that can severely stress a supply chain. The supply chain and supply chain management is a critical operations management element for any major company to succeed and remain competitive in the global market. The supply chain is one of many pieces critical to maximizing value to the end customer and requires close management to minimize external impacts. If a company is relying on another company to supply the raw materials needed for their production line, then impacts to this other company could impact their supply chain. Careful risk management is needed to optimize performance. As a company expands into global markets and global suppliers, this risk and management challenge is multiplied. The global nature of the company could impact important activities such as transportation, funds transfers, suppliers, distributors, accounting and information sharing. Disruption to the supply chain can significantly reduce revenue, cut market share, inflate costs and threaten production. A major disruption would have obvious impacts to profit, but could have additional intangible impacts to the credibility of the company if products are not delivered on time.
Just In Time, Toyota Production, and Lean Manufacturing are productions systems intended to reduce costs, and waste associated with inventory and manufacturing.
In 1950s, Toyota has developed lean thinking. The Toyota Production System aspires to minimize waste and increase efficiency while at the same time enhances its product quality. From this initiative, Toyota managed to widen its competitive edge by employed fewer employees in the car production with a small number of flaw products.
In manufacturing process there are different steps and jobs needs to be done in specific ways and time such as sourcing the parts we need in the production, make the items, and shipping it for the customers.
...reduce cost to the business, customers and the environment. Lean production system can be seen really great operations strategy for Kellogg’s, however, the management need to look for methods, which enables the employees to understand the system better, therefore resistance can be avoided. In order employees to be motivated, there is a need for training before their work as well as involve them in the implementation procedure. Consequently, Kellogg’s would be more successful if the company carries out this program.