The Toyota Production Method
Brian McNeillie
SCM 298
May 9, 2006
Toyota is currently on its way to become the biggest car company in the world. This is the culmination of goals set back in the 1970s, where Toyota’s management decided that it would like to attempt to catch up with the American car companies in terms of efficiency and production but add there own twist. To get this Twist Toyota developed the Toyota Production System or TPS that is the main topic of this paper.
The fundamental crux that faced Toyota was this: Since its inception the car building assembly line, developed originally by Henry Ford, was developed to produce one similar item, very quickly and efficiently. As Henry Ford once said of his car selection “You can have any color as long as it is black”. Toyota wanted to offer more model selection to customers, thus producing less batches of each. This does not bode well for supply chain efficiency based off of the Ford Model. Therefore they needed to re-think the process that was used to build cars. They had to figure out how to make an incredibly flexible supply chain
Toyota first decided to look at the fundamental theory of car production, and began to implement a series of changes on the production floor. These ideas were implemented by Taiichi Ohno, who took ideas he learned from trips to America, and from initial experiences. Later he would document it and give it the name that itsis known as the Toyota Production System TPS. The fundamental 2 ideas of the system are Just-in-Time manufacturing and the visualization of problems on as supply chain known as Jikoda.
On a tour of the United States touring GM and Ford, a team of specialist for Toyota overlooked the operations. Interstingly there main idea though came not from the lines producing Mustangs and Malibu’s, rather they learned from something Americans all over walk into, supermarkets.
Taiichi Ohno looked to the supermarket as a model for the Just in Time theory. When one looks at it truly is quite different in the way it is operated and maintained. They have a huge product variation, movement of many goods very quickly (though fairly constant demand for many things), they have to maintain short lead times, as food is perishable. How does a supermarket cope? Retailers such as Wal-Mart and King Soopers uses point of sales information. The instant an item is purchased it is acknowledged by a computer thus re-evaluating the on hand inventory. This computer takes the information and then instantly places a replenishment order for more when a preset numbers are gone. Then they would have many shipments at a time in order to meet the customer expectations. This system is very demand driven, and is actually quite effective as one can see, as very rarely does one walk into a supermarket and find that what they want is not there, but everything is usually fresh and ready to take home when demanded.
So Toyota took this and decided that they would take this idea to there own automobile line. They would not begin production unless demand was actually there (most of the time, some sales forecasting does take place), then by shortening lead times. They also did this in each part, only producing parts when needed and replenishing only when needed, as opposed to stock piling on the production floor. This system is very different then the mass producers such as Ford. It allows flexibility as you can switch over parts more efficiently. Another advantage you don’t have to push one product batch through before another one can be brought to the table. With this flexibility, Toyota had an easier time easier time meeting demand as you can respond quickly to customer demand without wasting resources on the switchover or running into overage or underage costs.
Also with this Toyota drastically reduced the warehousing process on either end of the chain. They no longer had cars sitting around waiting for pickup, nor did they require the storage of parts in places, rather the just in time relieved them of the burden of cost associated with these. This meant they cut prices allowing them to gain price advantages. They then further tweaked there supply line innovating ideas to help create a more efficient system to compete with the Big 3 from the United States, who at the start of the process controlled most of the automotive market
Now originally this system seemed tough to run, and employee intensive. The problem was that for quality control to occur, the traditional model required an employee at every station, a “specialist” like working every single machine was the case. Tradition from years meant the lathes would be in one place operated by the lathe operators, then these men would transfer the lathed piece to the drillers, for drilling, who would then transport the drilled piece to the bolt setter. This process had much human inspection, but lots of time was spent with the product in transition and was employee strenuous, as sometimes all operators had to do was watch to ensure quality. In America the above cycle would be tough to break, as each of the above jobs had a union, as unions were based on a discipline. Japanese Unions were general, so Toyota decided that they would put more automatic checks, and also line up machines for processing, so a single operator could operate all 3. This decreased labor and decreased time in transporting cost, increasing manufacturing speed and response.
With this new system though, transfer of information and problems became vital to the success or failure of the line, because with just in time manufacturing anything that is produced must be perfect, because you have no backup stock for mis-production. This is where the Jikoda comes in. In order to effectively communicate information up and down the supply chain Toyota developed a whole new way of communicating line information to every worker in the production cycle and quickly respond to errors that occur up and down the supply chain.
The first major development in this essence from Toyota was the Kanban card, which was essential to implement the above system of having on hand products. The Kanban is a parts-movement system using cards and containers used to move from one work station during the manufacturing process. Kanban stands for Kan-card, Ban-signal. The Kanban concept is that a supplier or the warehouse should only deliver parts the factory floor when need only, so that there is little to no storage on the Production Floor. Within this system, workstations located along production lines only produce/ deliver desired components when they receive a card and an empty container, indicating that more parts will be needed in production. Should line interruption occure, only empty containers are filled, everything else stops so no funneling occurs as funneling decreases the efficiency of labor. In addition, Kanban limits the amount of inventory in the process by acting as an authorization to produce more inventory. Since Kanban is a chain process in which orders flow from one process to another, the production or delivery of components are pulled to the production line. These cards allowed Toyota to keep very tight knit controls on demand and production.
The other innovation on the floor Toyota Developed was the Andon. The Andon in ancient Japan were paper lanterns used in front of little shops at night to indicate if they were open or closed. Well the TPS gave the Andon gave this word a whole new definition in the Supply Chain. It was a simple idea at first, and idea that now seems quite simple. In order to communicate a shutdown, if any machine detected a problem in the supply chain, it would trigger a signal to the signboard over the factory floor. This made the entire process stop, and the problem addressed with a succession of asking why 5 times to get to the bottom of the problem. This means that every problem is addressed and recorded. This means the whole line knows the problem, knows the fix and every aspect up to the problem can be looked at and fixed, which means it shouldn’t occur again or another question series will be produced. This means that the supply chain is always becoming more refined.
These ideas were implemented by Toyota in order to become the leaders in there field. Now Toyota, 30 years later is the second biggest manufacturer of automobiles in the world, and has the shortest lead times and least production costs of any auto manufacturer. The most profitable company is also a perennial member of the best supply chains. The Toyota production system is applied in thousands of manufacturing processes, driving leading companies like Dell and Gateway. These companies show the true power of the TPS. But another question stems. Why was the Big player in the automaker, GM unable to keep pace, as it is now in debt, while Toyota in continually turning in profits?
GM is still the leading manufacturer of automobiles in the world. Its company arms include Buick, Cadillac, Chevrolet, GMC, Holden, Hummer, Opel, Pontiac, Saturn, Saab and Vauxhall. This represents almost 15% of all world car sales, and employ 340,000 people. And yet they are facing massive financial woes, struggling to match the previous glories.
In the new right now much is discussed about the GM pension and health benefits. Cureently they are paying almost 1,500 dollars per car to people who no longer work for GM. They have had major finance issues, as there bond are now classified as junk bonds and now no longer are looked upon as stable. Solutions to these problems involve renogtion of debt and contract and will probably be resolved. But another problem less discussed by the media is GMs failure to match Toyotas intricate production system.
As mentioned above the TPS would be difficult to implement because of the structure of the existing Union setup for specialization, and that hinder the evolution. But fundamentally GM never really innovated there supply chain. Yes all the trucks could be produced on a line, then the passenger cars of certain sizes in on plant, and could be distributed in this way. This was fine when demand remained constant. But they never developed the real depth of production possibilities of a Toyota line, producing the Camry, and at the same time could produce the Tundra with a weekends work at changing. Therefore when Toyota had a mass change, it simply changed its plants. GM faced a very different issue. If the overall demand for trucks went down, suddenly the production line lay empty, while possibly the car division was over worked. They then were no longer using full capacity, which cost money. The other plant would be short, and therefore more money is lost. This system is slowly changing as GM realizes there mistake, and now working on joint ventures for Toyota, should help GM stream line, though it is believed that only bankruptcy will help GM renegotiate its Union contracts in order to help try and change the impending slide.
Another problem GM ran into was it was the biggest, it was no longer pushing innovation. It would have multiple brands producing almost identical products in the same market, Such as the GMC Jimmy, Chevy Tahoe. The cars were indistinguishable from one another, but were competing against one another. This meant that the companies would have to focus on deals between the 2 companies pushing the cars, and thus allowed other competitors to enter the market rather easily and able to distinguish themselves quite easily, as GM was really not offering different standard.
GM has shown though that it can push new prducts and be successful. The revitalization of Cadilac has shown the can grab market if they offer the right products to the right place. They will still continue to innovate and won’t let Toyota pass them without a fight. So Toyota does face some challenges in the coming years.
With th change in computers, the whole world is changing with it. Toyota is no exception. Toyota is currently trying to integrate the new changes in. Currently Toyota has set a goal to cut its inventory holding in half of its current 3 months, which will be quite a feat. The just in time will be pushed to its limits, but they will be working hard to try and provide even more accurate demand info and push there production system eve further
The key components will start by redesigning of the existing operational systems, creating a data warehouse to interface with the system, and designing the interfaces between demand-estimating, supply-chain modules, and the supply-chain strategy. Basically they are refining the techniques in which information is acquired by companies, and thus producing even closer to instanteously. By converting info into IT they can also spread information instantly across the world, making production even for streamlined, as problems form across the lines can be solved and shared with little or no time between in every plant. This though increases the base knowledge of the basic employee on the plant floor, which takes time and can actually be problematic. Some managers in certain Toyota plants feel that too much information may be counterproductive. They say it may also decrease built in flexibility if too much weight is put on this info. Most industry experts say the IT revolution will come, whether Toyota wants it no or later, and Toyota would do best to embrace it early.
Also an new challenge facing Toyota is the alternative fuel systems becoming more and more demanded. These cars have even more unique parts, requiring new ways of production, making them more difficult to produce on the same line as normal car. With more developing alternative fuel sources suddenly the option that must be changed is going to to increase greatly. Toyota is already on the forefront, but in a burgeoning industry much can change very quickly and therefore Toyota will have to watch for rapid changes, and be able to tweak plants in order to catch any new development as quickly as possible, trying to make the chain even more flexible and also requiring again, more worker knowledge and training.
Toyota’s innovations have made it the envy of the automotive industry and continues to push the market it terms of how to handle production. Its models are studied in courses all over the world Its continuing innovation and dedication to its renewal guarantee its place in industry will be one of power for years to come