process improvement project: toyota

8/18/2019 Process Improvement Project: Toyota

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Process ImprovementProcess Improvement

Project: ToyotaProject: Toyota

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P-C( IMP-.(M(/T F- T-0-TA: TH(/((D F- T-TA1 23A1IT0 MA/A4(M(/T


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TA51( -F C-/T(/T

Introduction...........................................................................................2

Current Project Management o6 Toyota............................................2

upply chain o6 components...........................................................3

Total 2uality Management 7y Toyota................................................4

e8uirement -6 The Process Improvement..................................5

-7jectives o6 the Process Improvement........................................5

Implementation o6 T2M Process Improvement...............................6

9ido+a...................................................................................................6

9ust In time.........................................................................................7

an7an................................................................................................7

ai;en..................................................................................................7

mart Tool For Analysis.......................................................................8

Conclusion..............................................................................................9

e6erences...........................................................................................10


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P-C( IMP-.(M(/T F- T-0-TA: TH( /((D F-

T-TA1 23A1IT0 MA/A4(M(/T

I/T-D3CTI-/

Founded in 1937 by Kichiro Toyoda Toyota Motor Corporation i

head!uartered in "ichi# $apan. %nti& ear&y 2013 Toyota ha 'ore than

333#400 e'p&oyee (&oba&&y. The net re)enue *or the pat year +ere

dec&ared a ,216 -i&&ion# net inco'e o* ,9.47 -i&&ion and operatin( inco'e

o* ,13 -i&&ion Toyota "nnua& /eport# 2012. The product &ine *or Toyota

inc&ude ybrid e&ectric )ehic&e p&u( in hybrid# a&&e&ectric )ehic&e#

hydro(en *ue& ce&&# %# picup truc and Toyota /acin( e)e&op'ent

T/. n addition it a&o operate nonauto'oti)e action inc&udin(

aeropace# phi&anthropy# robotic and a(ricu&tura& techno&o(y Mor(an et

a&.# 2006. n the %K the 'anu*acturin( p&ant i &ocated at eeide# orth

:a&e +here on&y en(ine *or hybrid car are 'anu*actured throu(h

procein( o* a&u'iniu' catin(# ae'b&y and 'achinin(. The report

dicue the pro;ect 'ana(e'ent trate(ie +hich Toyota can de)e&op

*or it *urther pro(re.

C3(/T P-9(CT MA/A4(M(/T -F T-0-TA

$apanee baed 'anu*acturin( co'panie are on the road to ucce

a'on( the internationa& 'aret and thu capturin( the o)erea

production yte'. The acco'p&ih'ent o* their enterprie ha)e

increaed the interet o* or(aniation to+ard $apanee


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3PP10 CHAI/ -F C-MP-/(/T

A&oba&&y the auto'obi&e indutry ha a *oundation upon the co'ponentre!uired *or car 'anu*acturin( hence *or'in( a pyra'id. o+e)er there i

a diBerence bet+een the upp&y chain pyra'id in uropean 'aret and

$apanee 'aret Dau+e& et a&.# 2004. Thi i due to the occurrence o*

ndutria& /e)o&ution a in urope it too p&ace in &ate ei(hteenth century

a*ter the etab&ih'ent o* app&ied and auto indutrie +herea in $apan it

too p&ace durin( the 1930 +ith the de)e&op'ent o* indutria&iation.

ence Toyota a&o +a *orced to bui&d up the co'ponent indutrie +ith

it upp&ier. Current&y there are t+o 'ain co'ponent upp&ier *or Toyota

inc&udin( ippon eno Co'pany @i'ited and "iin eii Co'pany@i'ited +hich ho&d an ut'ot i'portance *or Toyota. Fo&&o+in( i the

u''ary *or Toyota *or the ey upp&ier Christopher, 2012E

Feature Description

uantity o* upp&ier 200uantity o* co'ponent G)er 2 bi&&ion unit

Month&y purchaab&e 150#000 indDurchaed co'ponent +orth G)er , 250 Mi&&ion per 'onth

itribution o* upp&ier

G)erea

%K# %"# France# Canada# +eden

itribution o* upp&ier

ationa&

Toyo ditrict# Toyota ditrict and Gaa

ditrict

Toyota *o&&o+ a trict princip&e *or purchain( the co'ponent *ro'

upp&ier +hich inc&ude that it doe not acno+&ed(e oBer *ro' &o+

priced co'ponent unti& the ori(ina& price i con


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ad)anta(e a&on( +ith eIce&&ent 'ana(eria& and techno&o(ica& apect.

:ith *orei(n upp&ier it dea& indirect&y a co'pared to the nationa&

upp&ier pear# 1999.

Toyota i trict +hi&e dea&in( +ith upp&ier and *o&&o+ the ru&e re(ardin(

baic contro& o* co'ponent tranaction +hi&e *o&&o+in( &on( ter' tab&e

tranaction. Gn thee (round it tend to create &i*e&on( properity a'on(

the partie *or *aci&itatin( !ua&ity aurance *or the cuto'er. :hi&e a

dea& i bein(


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Toyota +ho&&y tre upon the cuto'er a their


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Mana(e'ent Droce MD +a *o&&o+ed *or acco'p&ihin( the ta

yer# 2002E

IMP1(M(/TATI-/ -F T2M P-C( IMP-.(M(/T

The baic ai' *or Toyota i to pro)ide peop&e +ith product that are

troub&e *ree and are eIact&y dei(ned +ith repect to peci


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$idoa re*er to the aptitude o* 'achinery and hu'an *or detectin(

ano'a&ou and abnor'a& condition in the product# 'ateria& and e)en

'ethod +hich are *o&&o+ed *or acco'p&ih'ent o* ta. Thi i done *or

pre)entin( *uture abnor'a&itie or 'a&*unction in the yte'. Toyota ue

thi ntation proce contro&&in( 'ethodo&o(y *or tructurin( !ua&itythrou(h the pre)ention o* 'a production o* ubtandard product.

"dditiona&&y the 'ain ob;ecti)e a&o inc&ude the pre)ention o* da'a(e to

e!uip'ent and too& due to an abnor'a& condition and eparatin(

'achine +or *ro' hu'an +or. For achie)in( thee ai' Toyota

reor(anied it tructure +hich can &end a hand in pro'otin( the

upporti)e yte' and too& +hich can hand&e the abnor'a& condition

Baudin, 2007.

For enurin( the 'aintenance o* !ua&ity a'on( a&& product Toyota

tructured an inpector +ho ued con)entiona& 'ethod *or inpectin(and eIa'inin( the


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or :D and e&i'ination o* a&& in)entory *or 'anu*acturin( and increain(

eJcacy in each part o* the yte'. The uabi&ity o* toc bui&d up +a

re'o)ed a eIce a'ount o* toc cou&d 'ean the prob&e' in

production yte' +hich are hidden and ided o)er throu(h +hich

+orin( ite i ne(ati)e&y aBected. :D he&p to per*ectin( the procein(o* in)entorie +ith increaed operationa& rate. Du&& yte' +a a&o

i'p&e'ented in the production yte' *or eepin( an eye on production

chedu&e. The o)er and under production o* part +ere &i'ited throu(h

uin( thi 'ethodo&o(y a 'andatory !uantity o* part# 'ateria& and

e!uip'ent +ere produced in the producin( unit. Thi *urther *aci&itated

the ba&ancin( o* uptrea' and do+ntrea' procee *or rei'burin( the

indicretion o* product ch+eiter# 2012.

A/5A/

Kanban re*er to the )iua& i(na& (i)en or recei)ed +hich encapu&atethe intruction *or producin( product or pu&& out to de)e&op a product.

ence it inc&ude +ithdra+a& Kanban and i(na& Kanban. Toyota e'p&oyed

the pu&& yte' throu(h proper Kanban techni!ue *or a&&o+in( the ?o+ o*

'anu*actured product. The production +a percei)ed +hen the cuto'er

inti'ate Kanban *or rep&ace'ent o* purchaed product. ence the

cuto'er order +a then tran*erred to hi(her authoritie *or the


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inc&uded i*tin( eiri# ortin( eiton# +eepin( and c&eanin( eio#

pic and pan eietu and utain hitue. Thee ru&e 'ade certain

that each 'e'ber +a ea(er&y participatin( *or eBectua& reu&t hi'iu#

2000.

MAT T--1 F- A/A10I

M"/T *ra'e+or re*er to peci


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rate. The 'ethodo&o(ie *or cah ?o+ +ere ued inc&udin( nterna& /ate

o* /eturn and et Dreent a&ue +hich deter'ined the pri'ary needed

in)et'ent and eIpected return and cope on the pro;ect "tinon#

1999.

C-/C13I-/

Toyota i the &eadin( car 'anu*acturer in the +or&d +ith hi(h


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(F((/C(

"'aaa# K. 2002. =e+ $T>E " ne+ 'ana(e'ent techno&o(y princip&e at

Toyota. International Journal of Production Economics# 802# 135144.

"tinon# /. 1999. Dro;ect 'ana(e'entE cot# ti'e and !ua&ity# t+o bet

(uee and a pheno'enon# itH ti'e to accept other ucce criteria.

International journal of project management # 176# pp 337342.

-audin# M. 2007. Working with Machines !he nuts and "olts of lean operationswith Jidoka. Droducti)ity Dre.

-in(# M. .# @ounbury# $. :. 2000. Gpenne and ;ob per*or'ance in %

baed $apanee 'anu*acturin( co'panie. Journal of #usiness and Ps$cholog$ #

1%3# pp 515522.

-oyer# /.# Charron# .# $ur(en# %.# To&&iday# . d.. 1998. #etween Imitation

and Inno&ation !he !ransfer and '$"ridi(ation of Producti&e Models in the

International )utomo"ile Industr$ !he !ransfer and '$"ridi(ation of Producti&e

Models in the International )utomo"ile Industr$ . GI*ord %ni)erity Dre.

Chun(# /. -.# K&einer# -. . 2012. iectin( ToyotaN +oe. Industrial

Management*+orcross# ,%1# 12.

Chritopher# M. 2012. -ogistics and suppl$ chain management . Dearon %K.

yer# $.# obeoa# K. 2002. Creatin( and 'ana(in( a hi(h per*or'ance

no+&ed(eharin( net+orE the Toyota cae.

art'an# F.# "hra


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process improvement project: toyota

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