This document provides background information on Toyota Motor Manufacturing, USA Inc. It discusses the company's founding in 1937 in Toyota City, Japan. It produces over 5.5 million vehicles per year and has 56 manufacturing plants across 6 continents. The document also summarizes a case study on issues Toyota is facing with its seat supply from Kentucky Framed Seat, including defects in materials and missing parts due to increased production demands and variety of seat models. Possible solutions discussed include increasing safety stock of seat varieties and improving quality control and detection of issues.

1. Welcome
TOYOTA MOTOR MANUFACTURING,
U.S.A. INC

2. Group Members
Name ID No
Rabeya Akter 120318
Arna Banerjee 120324
Sumona Hossain 120336

3. Company background
 Toyota is 11th largest automotive
manufacturer
 Founded by Kichiro Toyoda in 1937
 Headquartered in Toyota City, Aichi
 Launched first car (SA Model) in 1947

4. Contd.
 Largest vehicle manufacturer
 Produces 5.5 million vehicles per year
 Annual sales of 397.05 billion yen
 56 manufacturing plants across
6 continents
 Employs 3,38,875 people

5. Case Summary of Toyota Motors Manufacturing
 TMM faces increasing problems with its seat supply.
 Kentucky Framed Seat (KFS), is responsible for the major problems.
 Major encountered defects are material flaws and missing parts.
 Occurring with an increase in varieties and demand for the seats.
 TMM must address seat issue to ramp up Camry Wagon production.

6. Causal Factors

7. Probable Solution
Safety stock Seat
varieties.
Quick
Detection

8. QUALITY CONTROL
DEPARTMENT
 Procurement schedule should
match with production schedule.
 Seat material would be provided at
the time of procurement of seats.
 A quality check after
manufacturing car.
 Direct link between production
and operation department.

9. MANUFACTURING AND INSTALLATION

10. Inventory Management Department
Information on Kanban cards for inventory movement
A Kanban Card include-
 A part code number, its batch size, its delivery address and other related
information.
 Cards are used by PC department to determine appropriate kanban
range.
 Assembly group leaders adjust the number of circulating Kanbans for
each part within the set range.
 It will avoid team runs out of every parts.

11. its principles….
JIT
PC relied on the extensive forecasting and planning that TMC performed
for worldwide markets.
JIDOKA
Production will be stopped at any deviation of need and value is found.

12. Hijunka practice
It has two purposes…
 Spreading out the demand for parts
 Offsetting cars that required a particular operation

13. SUPPLIERS HANDLING
Based on the principle of
 “Long-term stable transaction”,
 “Basic control of component transaction”
On this contract Toyota confirms to promote
 Long lasting prosperity for both parties
 An ideal quality assurance for customers.
Hoping that-
 Perfect quality control is carried
 Basic rules of quality control for identifying defective
goods.

15. Recommendations…
Assisting suppliers in improving systems of management such
as:
 Toyota quality Control Reward
 Guidance of Toyota Production system (Kanban System)
 Mutual development by supplier’s organization and etc.