Toyota Operation+Management Spring11 | Toyota | Tire

Toyota Motor Operation Management Corporation Toyota Motor Corporation

Prepared by: Mussina Madina 20084630 Bakhit Sultanbayeva 20071498

Instructor: Dr. Ha Jin Hwang , Ph.

SPRING 2011

OM5202 OPERATIONS MANAGEMENT

OUTLINE
1. Introduction: Company Overview 2. OM Decisions: 2.1 Toyota Production System 2.2 Total Quality Decision 2.3 Process and Capacity Design 2.4 Human Resources 2.5 Supply Chain 2.6 Inventory 2.7 Maintenance 3. Toyota car’s problems 4. Conclusion& Recommendations

and has a majority stake in Daihatsu and Hino Motors and minority stakes in Fuji Heavy Industries (Subaru) and Isuzu Motors  Toyota Motor Corporation was established in 1937 by Kiichiro Toyodo on the basis his father’s company Toyota Industries  2010.Introduction: Toyota overview  Toyota Motor Corporation (TMC) is a Japan-based and multinational company . the world's largest automaker by sales. and is the second largest automaker in the United States by sales  Toyota also owns the Lexus and Scion brands. Toyota has 522 consolidated subsidiaries and 226 affiliates .

including the kanban (information card). andon (display board). and standard work practices  Just-in-time is producing only what's needed and transferring only what's needed.  "pull" system where process are based on customer’s demand.Toyota Production System  TPS emphasizes continuous improvement. and poka yoke (error prevention) were used to implement the pull system. . respect for people.  "pull" system tools.

and get rid of everything else. because defective items will move on to the next stage  That's where the concept of visual control comes from-the andon electric light board  When the problem is clear then use kaizen"improvement" or "change for the better.” . “Identify activities that add value to raw material.Toyota Production System  It is important to halt the process.

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Total Quality Management  TQM is searching for superior quality from the development stages to manufacturing a product. 1. People . Planning 3. Production 4. Philosophy 2.

Process and Capacity Design The Right Process Will Produce the Right Results  Principle 1 Work processes are redesigned to eliminate waste (muda)  Principle 2 Use "pull" systems to avoid overproduction  Principle 3 Level out the workload .

thoroughly tested technology .Process and Capacity Design  Principle 4 Build a culture of stopping the production line to fix problems  Principle 5 Standardized tasks and processes are the foundation for continuous improvement.  Principle 6 Use visual control so no problems are hidden  Principle 7 Use only reliable.

HUMAN RESOURCES •Toyota – developing people booklet •Toyota Way 2001 •Toyota Institute Toyota developing people booklet .

S Reduce setup Times 2) Q Total Quality Control .M quality measures .INVENTORY 1) F Design Flow Process .L Reduce lot sizes .M Preventive maintenance .C worker compliance .W Balance workstation capacity .O Link operations .F Redesign/relayout for flow .I Automatic inspection .

W Worker participation 3) S Stabilize Schedule .B Backflush .D Demand pull .M fail-safe methods .UC Underutilize Capacity 4) K Kanban Pull System .L Reduce lot sizes .W Establish freeze windows .INVENTORY .S Level schedule .

L Reduce lead time .S Stores .D Frequent deliveries .Q Quality expectations 6) I Further Reduce Inventory in Other Areas .T Transit .C Implement conveyor belts to reduce motion waste .INVENTORY 5) V Work with Vendors .U Project usage requirements .C Implement carrousel to reduce motion waste .

P Standard production configuration .P Standardize and reduce the number of parts .P Process design with product design .Q Quality expectations .INVENTORY 7) P Improve Product Design .

MAINTENANCE Level I This is a dealer recommended service Replace Engine Oil Replace Oil Filter Check and Top Off All Fluid Levels Inspect Condition of Hoses and Belts Inspect Complete Disc Brake System Set Tire Pressure Inspect All Lighting Systems .

MAINTENANCE Level II This is a manufacturer required service Replace Engine Oil Replace Oil Filter Check and Top Off All Fluid Levels Inspect Anti-freeze Protection Inspect Condition of Hoses and Belts Perform Tune-up Without Parts (all related parts and specifications are checked) Inspect Engine Idle and Timing Inspect Engine and Transmission for External Fluid Leaks Check Alignment by Test Drive Rotate Tires and Balance Fronts Set Tire Pressure .

I. Wipers.MAINTENANCE Level III This is a manufacturer required service Inspect Steering System Including Alignment Check by Test Drive Inspect Front Suspension and Ball Joints Rotate Tires and Balance Front Tires Set Tire Pressure Perform Tune-up Replace Spark Plugs Replace Air Filter Clean Throttle Plate (E. and Hinges Road Test Vehicle for Performance Quality Check .) Inspect Condition of Hoses and Belts Inspect Operation of Horn. and Heater Lube All Locks. Lights. Latches.F.

Fuel Tank Vapor Vent System Hoses and Fuel Tank Band .MAINTENANCE Level IV Inspect Drive Shaft Boots & Grease Repack Front Wheel Bearings (where applicable) Set Tire Pressure Inspect Exhaust Pipes and Mountings Perform Tune-up Replace Spark Plugs Replace Fuel Filter Replace Air Filter Clean Throttle Plate (E.) Inspect Camshaft Drive Belt (timing belt) Inspect Fuel Lines and Connections.I.F.

Toyota car’s problems .

Toyota RAV-4 2002 year of production Transmission Engine Electrical Other .

Toyota Camry 2002 year of production Transmission Engine AC Heater Other .

Toyota Camry 2007 year of production .

Toyota Corolla 2002 year of production .

aspx?id=76357  http://www.toyota.org/product/toyota-motormanufacturing-u-s-a-inc/an/693019-PDF-ENG  http://www.toyota-global.com/  http://www.slideworld.ca/  http://hbr.com/toyota_production.toyota.strategosinc.com/  http://www.com/evt/view.com/  http://www.toyotaproblems.ht m  http://www.References  http://www.xtimeline.com .

for attention!!! .

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