TYPICAL FACTORY LAYOUT vs

THE TOYOTA APPROACH

RACHEL TATE @00441881

VALERIE CARDOZ @00442956

1LEAN INTEGRATING DESIGN AND PRODUCTION

WHAT IS THE TYPICAL FACTORY LAYOUT IN MASS MANUFACTURING APPROACH?

WHAT IS THE APPROACH TO FACTORY LAYOUT IN TOYOTA?

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TYPICAL FACTORY LAYOUT vs THE TOYOTA APPROACHINTRODUCTION

Various factory process layouts.

Basic layouts for manufacturing facilities:

‘Static’ or ‘Fixed’ position build

Product based Layouts

Process based Layouts

The typical factory layout in mass manufacturing approach.

The approach to factory layout in Toyota.

Comparison between the two factory layouts.

Conclusion

2LEAN INTEGRATING DESIGN AND PRODUCTION

TYPICAL FACTORY LAYOUT vs THE TOYOTA APPROACH

TYPICAL FACTORY LAYOUT vs THE TOYOTA APPROACH

3LEAN INTEGRATING DESIGN AND PRODUCTION

BASIC LAYOUT TYPES

Source: http://www.memrise.com/

STATIC OR FIXED POSITION PRODUCTION

Parts and resources come together and are assembled at one place

This method is used to create large and complex products such as airplanes and ships.

TYPICAL FACTORY LAYOUT vs THE TOYOTA APPROACH

4LEAN INTEGRATING DESIGN AND PRODUCTION

BASIC LAYOUT TYPES

Source: Gaither & Frazier, 1999

2Raw Materials Components

4

51 3 7

6

PRODUCT-FOCUSED PRODUCTION

Subassemblies

Components

Raw Materials Components Subassemblies

Purchased Components & Subassemblies

Assem

blie

s

Assemblies Finished Products

Product or Material Flow

Production Operations

TYPICAL FACTORY LAYOUT vs THE TOYOTA APPROACH

5LEAN INTEGRATING DESIGN AND PRODUCTION

BASIC LAYOUT TYPES

Source: Gaither & Frazier, 1999

PROCESS - FOCUSED PRODUCTION

Product or Material Flow

Production Operations

Packaging and Shipping

PaintingFabricationRough Machine

FoundryReceiving & Raw Materials Storage

1Job X

1Job Y

Shear & Punch

Finish Machine Deburr Assembly

2 3

4

2 3 4

5

6

7

5

6 7

8

TYPICAL FACTORY LAYOUT vs THE TOYOTA APPROACH

TYPICAL FACTORY LAYOUT

6LEAN INTEGRATING DESIGN AND PRODUCTION

Traditionally, factory layouts focus on process based departments. Work is done in batches and organized through departments.

(Weber, 2012)http

s://w

ww.tigertr

ailers.

co.uk/Facto

ry

TYPICAL FACTORY LAYOUT vs THE TOYOTA APPROACH

TRADITIONAL FACTORY Each silo is as efficient as possible

Traditional layouts assume that more quantity is the key output.

Batch-and-queue system. Allows inventory to build up and wait. Theory is reduced change over and transport cost.

Product is pushed through to the customer

Traditional layouts usually optimize for a static design

Having the biggest facility or the fastest and largest piece of equipment is considered efficient.

Use of complex and expensive material handling systems installed to ‘automate’ the transportation waste. 

LEAN INTEGRATING DESIGN AND PRODUCTION 7

TYPICAL FACTORY LAYOUT

TYPICAL FACTORY LAYOUT vs THE TOYOTA APPROACHTYPICAL TOYOTA LAYOUT

Toyota wanted to match the production output of Ford. On analysis their constraints demanded a different process that would work in harmony with;

Smaller Space

Smaller Cash Flow

Greater model variety

Smaller Client base

By genchi genbutsu they found waste and defects running through the Ford system, they developed one-piece flow.

Lean manufacturing is about making “more and more, with less and less”

LEAN INTEGRATING DESIGN AND PRODUCTION 8

TYPICAL FACTORY LAYOUT vs THE TOYOTA APPROACHTYPICAL TOYOTA LAYOUT

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www.assemblymag.com

One-piece-flow focuses on the most efficient flow for the product.

The materials like people do not want to wait around for activity, the system keeps them flowing.

Defects are found quickly.

Movement is reduced through intelligent flow management.

TYPICAL FACTORY LAYOUT vs THE TOYOTA APPROACHTYPICAL TOYOTA LAYOUT

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www.assemblymag.com

Workstations are flexible, they can be altered to change their role/output and moved to create a different sequence.

Stations are flexible to changing workloads. More or less stations can be created in the process.

Standardisation of parts throughout car models reduces this need.

TYPICAL FACTORY LAYOUT vs THE TOYOTA APPROACH

LAYOUT AT TOYOTA

Processes are balanced with each other and ultimately to the demand rate or Takt time.

Lean layouts focus on reducing waste and increasing value in the process

One-piece-flow attempts to have no inventory and reduce hidden defects

Driven by customer demand. Pulled through the system

Standardization is fundamental to flexibility

Workstations are flexible to work with the demands of the product and customer needs

Employees are motivated to problem solve and inspect throughout the process. Machines/the process can be stopped to solve the solution

LEAN INTEGRATING DESIGN AND PRODUCTION 11

TYPICAL TOYOTA LAYOUT

TYPICAL FACTORY LAYOUT vs THE TOYOTA APPROACHTYPICAL TOYOTA LAYOUT

LEAN INTEGRATING DESIGN AND PRODUCTION 12

http://ocmis.blogspot.co.uk/2013/03/achieving-operational-excellence-and.html

TYPICAL FACTORY LAYOUT vs THE TOYOTA APPROACHTYPICAL TOYOTA LAYOUT

LEAN INTEGRATING DESIGN AND PRODUCTION 13

www.toyota.co.jp

TYPICAL FACTORY LAYOUT vs THE TOYOTA APPROACH

TRADITIONAL FACTORY

Departments are organized by function;

Each department with separate supervisor and specialized workers.

Forklift trucks are needed to move inventory between departments.

LAYOUT AT TOYOTA

Factory is organized into cells with various machines in sequential order.

Fewer workers, supervisors and forklift trucks.

Much less work in process and no finished goods in inventory.

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CONCLUSION

TYPICAL FACTORY LAYOUT vs THE TOYOTA APPROACHCONCLUSION

TRADITIONAL FACTORY

Typical batch-and-queue system

LAYOUT AT TOYOTA

One Piece Flow

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http://www.flowmotioncafe.com/batch-working-or-one-piece-flow/#post-comments

TYPICAL FACTORY LAYOUT vs THE TOYOTA APPROACHCONCLUSION

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TYPICAL FACTORY LAYOUT vs THE TOYOTA APPROACHREFERENCES

Flow Motion. (2015, 9 July). Which is more productive Batch or One-piece-flow? [weblog]. Retrieved from http://www.flowmotioncafe.com/batch-working-or-one-piece-flow/

Gaither, N., & Frazier, Gregory. (1999). Production and operations management (8th ed.). Cincinnati, Ohio : London: South-Western ; International Thomson.

Toyota. (2016). Children’s website. Retrieved 11th April, 2016, from http://www.toyota.co.jp/en/kids/car/cooperation.html

Weber, A., (2016). Lean Plant Layout. Retrieved 04th April, 2016, from, http://www.assemblymag.com/articles/89823-lean-plant-layout

Williams, D. (1994). Manufacturing systems : An introduction to the technologies (2nd ed.). London: Chapman and Hall.

Zheng, E. (2013, 31 March). Management Information Systems. [weblog]. Retrieved from http://ocmis.blogspot.co.uk/2013/03/achieving-operational-excellence-and.html

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TYPICAL FACTORY LAYOUT vs THE TOYOTA APPROACH

QUESTIONS?

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