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13 Cards in this Set
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Key points about Toyota. |
1. Toyota's annual profit is larger than most of their competitors namely: GM, Ford, Chrysler, etc. 2. Toyota has for decades been making profit every year on a consistent basis. 3. Toyota's top selling vehicles in the world are Camry and Corolla. 4. Toyota Lexus brand is known to be the leader in the world's luxury vehicles and has outsold brands like BMW, Cadillac and Mercedes-Benz in the US. |
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5. Toyota invented lean production also known as TPS which has triggered a global transformation in virtually every industry in Toyota's manufacturing and supply chain philosophy methods over the last decade. |
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6. Toyota has the fastest product development process in the world. New cars and truck takes 12 months or less to design while competitors typically require two to three years.
7. Much of Toyota success comes from its outstanding quality reputation. customers know that they can count on their Toyota vehicle to keep working the first time and keep on working for years. |
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What does it take to be a lean manufacturer? |
1. It requires a way of thinking that focuses on making the products flow through value-adding processes without interruption (one-piece flow),
2. a pull system that cascades back from customer demand by replenishing only what the next process takes away as short intervals
3. A culture in which everyone is striving continuously to improve. |
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Define Lean Manufacturing |
It is defined as a five-step process: 1. Defining customer value 2. Defining the value stream 3. Making it flow 4. Pulling from the customer back 5. Striving for excellence |
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How did Taiichi Ohno define Lean manufacturing? |
What he said that they are constantly looking at the timeline from the moment the customer gives them and order to the point when they collect the cash. And what they are doing is to reduce the timeline by removing the non-value-added wastes. |
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What is the key to Toyota's operations? |
Flexibility |
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What was the critical Discovery made by Toyota in the course of implementing the Toyota way? |
When you make lead times short and focus on keeping production lines flexible, you actually get: 1. Higher quality 2. Better Customer responsiveness 3. Better productivity 4. Better utilisation of equipment and space |
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What are the conditions faced by most companies today? |
The need for fast, flexible processes that give customers what they want, when they want it, at the highest quality and affordable cost. |
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What continued to be the foundation for Toyota success globally in the 21st century? |
Toyota's main focus is on sustained, continuous, uninterrupted flow. |
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What does leveling the schedule (heijunka) mean? |
Leveling production means smoothening out the volume and mix all items produce so that there is little variation in production from day-to-day.
This is the foundation of flow and pull systems and for minimising inventory in the supply chain. |
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Why is the question off what value are we adding from the customer perspective very important? |
Because the only thing that adds value in any type of process - be it in manufacturing, marketing or development process - is the physical or information transformation of that product service activity into something the customer wants. |
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What are all the supporting tools of lean? |
1. Quick equipment changeovers 2. Standardized work 3. Pull systems 4. Error proofing |
