operations techniques of toyota motors

7/31/2019 Operations Techniques of Toyota Motors

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P R E S E N T E D B Y :

D I G V I J A Y S I N G H

S H I K H A R P U R I

A N K I T T Y A G I

OPERATIONS TECHNIQUESOF TOYOTA MOTORS


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Why Toyota

Toyota is now the world's largest carmaker.

Toyota sold 2.348 million vehicles in the first threemonths of 2007.

General Motors (GM) is

estimated to have sold

2.26 million cars andsmall trucks during

the same period.


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Toyota Callback Case

1.5 Million Toyotas Recalled for Brake and FuelPump Problems globally.

This hampered the Toyota Brand.

It was due to some error at the factory level. i.e.Production Operations were faulty.

If Marketing and Sales are the limbs of thecompany then Operations is surely theBackbone


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Toyota Motor Corporation

Headquartered in Japan

Founded by Kiichiro Toyoda in 1937

Revenues 18.9 trillion Yen in 2010

71,116 employees

Operations in North America, Latin America,Europe, Africa, Asia, Oceania and Middle East


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Toyota Production System (TPS)

Definition: The production system developed by ToyotaMotor Corporation to provide best quality, lowest cost, andshortest lead time through the elimination of waste.

TPS is comprised of two pillars, Just-in-Time and Jidoka(Autonomation - Automation with a human touch)

TPS is maintained and improved through iterations of

standardized work and kaizen (continuous improvement),following PlanDo-Check-Act (PDCA Cycle from Dr.Deming), or the scientific method.


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JIT In Toyota

Eliminate waste of all kinds by producing orsupplying materials only when they are needed.

Produce only the necessary products, at the

necessary time and in the necessary quantity JIT allowed Toyota to do away with inventory cost

such as raw material, WIP cost, FG Cost.


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Pull System Of Manufacturing

JIT was based on reverse reasoning and the workingof the production line started at the point ofcustomer demand.

RawMaterials

Demand AssemblyParts

Supply


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Push System Of Manufacturing

If JIT is achieved throughout the organization, thenthe inventory would be completely eliminated

ProductRaw

MaterialPart

SupplyAssembly


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Kanban

Implementing JIT is difficult as it require thousandparts/components to manufacture.

Kanban means signboard in Japanese was a tool

to effectively control production quantities Workers of a process needing components wrote the

details about the kinds of units needed and thequantity in which they are needed on a card called

the Kanban.


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The system was made up of a fixed number of containers, eachholding a certain fixed quantity of parts


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TQM

Total quality management or TQM is an integrativephilosophy of management for continuously improvingthe quality of products and processes.

Total Quality Management (TQM) is a management

approach to long-term success through customersatisfaction, all members of an organization participatein improving processes, products, services and theculture in which they work.

It is important because every company needs alloperation should be done right the first time.

The aim of the combination of quality and managementis increasing business and reducing losses due to

wasteful practices to low cost.


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TQM & TOYOTA

Originally TQM started was TPM "Total ProductiveMaintenance". It was invented by Toyota, not by W.Edwards Deming or by the U.S. Navy.

Before TPM problem was that workers followed the

basic American practice which was to operate amachine until it broke and only then call in anengineer to fix the machine. This cause extra timeconsumption.

The US Navy began to develop what it called "TotalQuality Management" around 1980 which was

based on a collection of Japanese models, the mostimportant of which was Toyota's TPM.


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Steps taken by Toyota to improve Quality

Maintain quality through team work-work as ateam to continuous improvement in quality.

High quality start with the consumer-focus not

only on economic issue but also on customer life. Ask WHY five times about every matter-Go

directly to source and keep asking why, when problemarise.

Building quality into process-Standard in process Good thinking. Good products-encourage creative

idea for quality improvement.


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THANK YOU

operations techniques of toyota motors

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