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Project Number 4
Toyota Production System, TOC and Production Control
Objective: Demonstrate understanding of
• TPS,
• Lean Manufacturing,
• JIT, and
• Theory of Constraints
through analysis of a case study.
Method:
A. Read the case Toyota Motor Manufacturing USA Inc
B. Prepare detailed answers to the following questions.
1) List and provide a quick definition of the key terms used in the case, be sure to go beyond what is listed in the glossary.
2) What are the prerequisites to using TPS that are identified in the case? Briefly explain why each is required.
3) Estimate the labor productivity (not including benefits) of the assembly operation using $’s/$’s. Does this number seem high or low? Explain your thinking.
4) If all assembly stations have a cycle time of 57 seconds, is there no bottleneck? Explain.
5) Explain the term Andon and the meaning and impacts of the yellow and red lines in each assembly station. Be sure to explain what the goal is for this system?
6) Describe the production planning and production control processes in your own words. Be sure to explain the example of how seat installation is linked to the assembly line and how production is linked to sales forecast.
7) Based on your answer to the above question, is this really a pull system? Explain.
8) What qualities are required to be a team leader or manager in this type of production system?
Do you think most traditional production supervisors could be successful in this environment? Why/Why not?
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