Toyota Production SystemPresentation Transcript
Toyota Motor Corporation - with an overview of “ TKML ” and “ Toyota Production System ” Welcome
World's third largest automaker
Global sales totaled 6.17 million units in 2002
Toyota has 45 manufacturing companies in 26 countries
Toyota employs 264,000 people worldwide
Markets vehicles in170 countries
Net sales 16,054.2 billion yen
Toyota Motor Co. Ltd was established by Kiichiro Toyoda in 1937 as a spin-off from Toyoda Automatic Loom Works
Toyota launched its first small car (SA Model) in 1947
Production of vehicles outside Japan began in 1959 at a small plant in Brazil
'Toyota Production System’ was established in 1970 by Taiichi Ohno. Based on the principles of Jidoka , Just-in-time and Kaizen , Reduction of inventories and Defects in the plants of Toyota and its suppliers
TOYOTA GLOBAL VISION
Be a driving force in global regeneration by implementing the most advanced environmental technologies
Creating automobiles and a motorized society in which people can live safely, securely and comfortably
Promote the appeal of cars throughout the world and realize a large increase in the number of Toyota fans .
Be a truly global company that is trusted and respected by all peoples around the world
Toyota’s sales in comparison to other manufacturers (in‘000) * Data for 2002
Toyota Kirloskar Motors Ltd.
Toyota Kirloskar Motors Ltd
Established in 1997
Started as a 74:26 partnership between Toyota and Kirloskar
At present the stake of TMC is 99%
TKML manufactures three models in India namely Qualis Corolla and Camry
TKML plans to introduce the Land Cruiser and other international models over time
Toyota Kirloskar Auto Parts’ (TKAP) is a 100-per cent export oriented auto transmission plant at Bidadi, Karnataka.
The Qualis Story..
Launched in 2000
A MUV marketed as easy to ride spacious family car
40% of MPV segment
TATA Sierra ,Safari
The Qualis story contd…
New Qualis launched recently
Faces competition from future entrants like GM Panther ,M&M Rexton Ford Everest
To be replaced with a new intl model
Toyota Production Systems an overview of Jidoka , Just-in-time and Kaizen , Reduction of inventories and Defects
TPS Myths and Realities
Tangible recipe for success
Management project and program
Set of tools for implementation
System for production floor
Way of thinking
Focus on total customer satisfaction
Environment for teamwork and improvement
Elements of TPS
The SMED Program.
Highlight Problems (Jidoka).
Gradual Elimination of Waste.
Continuous Improvement (Kaizen), Root-Cause Analysis (5-whys?) and Fool-proofing (Poka-Yoke), 5-S.
Stable Production Schedules (Heijunka)
Toyota’s Management Philosophy
Focus on JIDOKA
Separately positioned Processing
Continuous Flow Processing
Traditional “Buffered” Supply Chain Assembler 2 nd Tier 1 st Tier Flow of Production Flow of Information Customer Demand
The Just-in-Time Supply Chain Toyota 2 nd Tier 1 st Tier Flow of Production Flow of Information Customer Demand
Expectations from Suppliers
Hours (not days) lead time.
Rapid response capability (not from stocks).
Delivery to assembly line at the right time in the right sequence without inspection.