Friday, October 23, 2009

Objectives to reach the Toyota Production System

The Toyota Production System establishes several points to cause that the objectives of the four previous concepts are reached and that they are the base of the Toyota Production System.
  1. KANBAN System is an information system that controls the production of necessary articles in the necessary amounts, the necessary time, each process of the company and also of the companies’ suppliers. It establishes a production system in which the products are hauled by the following station; the products cannot be pushed by the first station. The products are hauled to the rate those are needed (called PULL System). The last station is the one that marks the rate of production.
  2. Constant production, that means that the line of production no longer this jeopardizes to manufacture a single type of product in great lots. However, the line produces a great variety of products every day in response to the variation of the demand of the client. The production is obtained adapting the changes of the demand daily and monthly.
  3. Reduction of the Set-up time (S.M.E.D.). The Set-up time is the amount of necessary time in changing a device of an equipment and preparing that equipment to produce a different model, but to produce it with the quality required by the client and without incurring costs it company and to obtain with this, to reduce the time of production in all the process. The product that arrives first the market enjoys a high percentage of gains associated with the initial introduction of the product.
  4. Standardization of operations: One is to diminish the number of workers, balancing the operations in the line. Assuring that each operation requires of the same time to produce a unit. The worker has a routine of standard operation and maintains an inventory in constant in process.
  5. Multifunctional distribution of machines and workers, who allow to have a force of very flexible work, which must of or being trained and to have a great versatility that is obtained continuously through the rotation of the work and they evaluate and they review the standards and routines of operation, and the machines could be placed in distributions in the form of “or” where the responsibility of each worker will be increased or diminished following the work to realize in each product.
  6. Improvement of activities, which are focused to reduce costs, to improve productivity, to reduce the work force, to improve the moral of the employees and this improvement carries out through work parties and system of suggestions.
  7. Visual control systems that monitor the state of the line and the flow of the production, with very simple systems, for example, some lights of different colors that indicate some abnormalities in the line of production. Some other visual controls like leaves of operations, digital cards of KANBAN, displays, etc.
  8. Quality control in all the company, that promotes improvements in all the departments, by means of the action of a department and reinforced by other departments of the same company. Having special attention in the meeting of directors to provide that the communications and cooperation in all the company.

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