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The Toyota Production System and On Time Collision Repair

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'The average time it takes to complete a step or series of steps ... Mura: Inconsistent or irregular processes. Muri: Overburdening a process. Eliminating Waste ... – PowerPoint PPT presentation

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Title: The Toyota Production System and On Time Collision Repair


1
The Toyota Production SystemandOn Time
Collision Repair
Randy Profeta Toyota Motor Sales USA, Inc.
2
On Time ConfigurationLight Damage Line
3
On Time Configuration(Alternative Track-style
Layout)
4
On Time ConfigurationHigh Production Light
Damage Line
5
Discussion Topics
  • Ideal Shop Layout / Equipment Configuration
  • Cycle Time Defined
  • Toyota Production System (TPS) Concepts

6
Cycle Time
  • The average time it takes to complete a step or
    series of steps within a process before starting
    over
  • Cycle Time must include Idle Time, time for
    Work-in-Process (WIP), and In-Transit Time

7
Cycle Time Milestones
  • Vehicle Received
  • Production Started
  • Production Complete (ready for delivery)
  • Vehicle Delivery

8
TPS Concepts
  • Lean Production, Do More with Less
  • Identify Takt Time, The Pulse of the Market
  • Focus on Single Piece VS Batch Processing
  • Kaizen
  • Concentrate on eliminating the Three Ms

9
The Three Ms
  • Muda
  • Waste
  • Mura
  • Inconsistent or irregular processes
  • Muri
  • Overburdening a process

10
Eliminating Waste
  • Seven Types of Waste
  • 1. Overproduction Ahead of Demand
  • 2. Waiting for the Next Step (Idle Time)
  • 3. Unnecessary Movement of Materials, Cars
  • 4. Over-processing
  • 5. Excessive Inventories
  • 6. Unnecessary Movement of People
  • 7. Production of Defective Products

11
Kaizen
  • Kai - To Change and Zen - Make Better
  • Put aside preconceived ideas
  • Associates are the experts, solicit their ideas
  • Use the Five Whys
  • The Status Quo is Unacceptable
  • Improve Constantly

12
Implementing TPS
  • Internal VS External
  • Single Piece VS Batch Processing
  • Understand Takt Time and Develop Flow
  • You Cant Manage What You Cant Measure
  • Get Buy-In
  • Decide How to Deal With Those that Dont

13
On Time Concepts
  • Do not start production until all parts are on
    hand and a complete Work Order has been prepared
  • Group Like-jobs, Separate Light-damage Vehicles
  • Eliminate Starts and Stops
  • Use High Quality Materials to consistently
    produce high quality finished products

14
On Time Configuration(Cycle Time 90 min. /
9.0 hours)
15
On Time Configuration(Cycle Time 30 min. /
5.0 hours)
16
Resources
  • The Machine That Changed the World
  • James Womack Daniel Jones
  • Harper Collins, 1990
  • Lean Thinking
  • James Womack Daniel Jones
  • Simon Schuster, 1998
  • The Toyota Production System
  • Yasuhiro Monden Taichi Ohno
  • Institute of Industrial Engineers, 1983
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