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Toyota Case Study Answer
Toyota Case Study Answer
Group: 1
1. As Doug Friesen, what would you do to address the problem? Where would you focus
your attention and solution efforts?
The major problem that Doug, manager of assembly, needs to address is of Seat
Problems. Due to seat problems, production level is decreasing and which resultant
leads to increase in overtime works, lead-time and off-time vehicle inventory.
The major problem that is observed is improper seat quality management in KSF.
Most of the seat problems were occurring because of this mismanagement like,
wrong, missing and broken parts, wrinkles and missing bolster.
Also, KSF inspection of seats before shipping is not proper. There need to check the
method followed by KFS while inspection of seats because several of defective seats
are being send as fit. May be by providing more training to the worker this problem
could be solved.
Also, there was ineffective feedback system, due to which Doug was not able to
reach the specific solution for the seat problems. So, by properly sharing and
discussing all the feedbacks may gave best optimum solution to the problem.
4. Use of plastic hooks as company was using metal hook which can cause body of the
consumer some damage to reduce that company can use plastic hooks which will do the
work as well as will no harm the costumers to.
3. Where does the current routine for handling seats deviated from TPS?
Toyota Production system was based on the principles of Just In Time (JIT) and JIDOKA which
stated that production should be stopped when problems are detected.
a) Deviations from JIDOKA As it implied that production should be stopped when problems
surfaced but as in the case of defective seat problem production was not stopped and car passed
through assembly line with defective seats in it. Car was taken to Code 1 clinic area to detect the
problem and then to overflow parking area for seat replacement.
b) Deviations from JIT principle As it stated that produce what was needed and when it was
needed. So it aimed at reduction of waste and inventory but in routine for handling of defective
seats cars were moved to overflow parking area where seat replacement was done so it resulted
in increase in inventory as well as waste. Secondly seats with no defects were not produced at a
time when they were needed.
These deviations occurred because the production people knew that stopping production was too
expensive and it was possible to finish the car without seats in it.