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3 Vital Elements:
A time-based strategy
The Toyota Production System Standard Operations
Traditional View
Sales Price
Mfg. Cost
Sales Price
Profit
New View
Sales Price
Mfg. Cost
Sales Price
Produce
Service
(Customers)
Business Resources
Sales
Define
Produce
Customer Service
Business Resources
OP 2 OP 1 RM WIP
Time-Based Manufacturing
OP 3 O P 1 OP 2
FG
RM
VA VA VA
60
65
70
75
80
85
90
95 100
VA VA VA
Typical Approach
VA VA VA
Preferred Approach
Types of Waste
Overproduction
Defects
Unnecessary inventory Inappropriate processing Excessive transportation Waiting Unnecessary motion
Waste Causes
Facility layout Excessive setup times Incapable process Poor preventive maintenance Uncontrolled work method
Lack of training
Boredom Production planning/scheduling
J I T
J I D O K A
JIT Principles
Pace to Takt time One piece flow operations
Takt Time
The word Takt is of German origin having its meaning most closely associated with musical rhythm Like a heartbeat it should not be arrhythmic Must have a couple of known paces, but these paces should not change every day
We need one unit every .55 minutes or one unit every 33 seconds
Batch
Flow
1-Piece Flow
Jidoka Principles
Separation of Machine and Operator
Stop the Line Authority
Poke Yoke
Quantity Time
Model Mix
Monthly Schedule (3200 units) Model A 1600 units
5 10
80
A
80
A
80
A
40 40
B C
40 40
B C
40 40
B C
40 40
B C
20
Day