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 cars problems 4. Conclusion& Recommendations

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, 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 fathers company Toyota Industries 2010, Toyota has 522 consolidated subsidiaries and 226 affiliates

Toyota Production System

TPS emphasizes continuous improvement, respect for people, 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 customers demand. "pull" system tools, including the kanban (information card), andon (display board), and poka yoke (error prevention) were used to implement the pull system.

Toyota Production System

It is important to halt the process, 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, and get rid of everything else.

Total Quality Management

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

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

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, thoroughly tested technology

HUMAN RESOURCES
Toyota developing people booklet Toyota Way 2001 Toyota Institute

Toyota developing people booklet

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

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

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

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

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

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.F.I.) Inspect Condition of Hoses and Belts Inspect Operation of Horn, Wipers, Lights, and Heater Lube All Locks, Latches, and Hinges Road Test Vehicle for Performance Quality Check

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.F.I.) Inspect Camshaft Drive Belt (timing belt) Inspect Fuel Lines and Connections, Fuel Tank Vapor Vent System Hoses and Fuel Tank Band

Toyota cars 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

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

for attention!!!