tps

2. Consumer Reports 2.810 T.G.Gutowski 10/29/01

3. 2.810 T.G.Gutowski 10/29/01 Toyota vehicle sales 2002

5. Three Major Mfg Systems from 1800 to 2000 2.810 T.G.Gutowski 10/29/01 1800 1900 2000 Machine tools, specialized machine tools, Taylorism, SPC, CNC, CAD/CAM Interchangeable Parts at U.S. Armories Mass Production at Ford Toyota Production System

6. Key Elements for New Mfg Systems 2.810 T.G.Gutowski 10/29/01 Element/ System Need of Society Work Force Motivation Enabling Technology Leader Resources Interchange-able Parts Military “ Yankee Ingenuity” Machine Tools, Division of Labor Roswell Lee/ John Hall U.S. Govt Mass Production Trans- portation $5/day Immigrant Moving Assembly Line,etc Henry Ford Earnings Toyota Production System Post War Jobs, Security CNC, Integration of Labor Taiichi Ohno Japanese Banks

7. Q. By what method did these new systems come about? A. Trail and Error 2.810 T.G.Gutowski 10/29/01

8. History of the Development of the Toyota Production System ref; Taiichi Ohno 2.810 T.G.Gutowski 10/29/01 1945 1975

10. Summary of Assembly Plant Characteristics, Volume Producers, 1989 (Average for Plants in Each Region) 2.810 T.G.Gutowski 10/29/01

11. Cost Vs Defects Ref. “Machine that Changed the World” Womack, Jones and Roos 2.810 T.G.Gutowski 10/29/01

15. Cost Vs Automation Ref. “Machine that Changed the World” Womack, Jones and Roos 2.810 T.G.Gutowski 10/29/01

18. Current Value Stream Map 2.810 T.G.Gutowski 10/29/01

19. Future Value Stream Map 2.810 T.G.Gutowski 10/29/01

20. Manufacturing System Design Decomposition (MSDD) 2.810 T.G.Gutowski 10/29/01 ROI Sales Costs Investments Lower level actions quality predictable output delay reduction  resolving problems 

22. TPS Cell 2.810 T.G.Gutowski 10/29/01

23. Standardized Fixtures 2.810 T.G.Gutowski 10/29/01

27. Manufacturing System Design Decomposition (MSDD) 2.810 T.G.Gutowski 10/29/01 ROI Sales Costs Investments Lower level actions quality predictable output delay reduction  resolving problems 

28. Example from Cochran – Minimize production disruptions 2.810 T.G.Gutowski 10/29/01

31. Takt Time – to pace production 2.810 T.G.Gutowski 10/29/01 Calculate Takt Time per month, day, year etc. Available time includes all shifts, and excludes all non-productive time (e.g. lunch, clean-up etc). Product demand includes over-production for low yields etc.

33. Engines shipped over a 3 month period at aircraft engine factory “B” 2.810 T.G.Gutowski 10/29/01

34. Engines shipped over a 3 month period at aircraft engine factory “C” 2.810 T.G.Gutowski 10/29/01

35. On-time performance of engine plants 2.810 T.G.Gutowski 10/29/01

36. Push and Pull Systems 2.810 T.G.Gutowski 10/29/01 Machines Parts Orders 1 2 3 4

37. Push Systems – Order arrives at the front of the system and is produced in the economical order quantity. Q. How long did it take for the order to go through the system? 2.810 T.G.Gutowski 10/29/01 Time = 3 Time = 2 Time = 4 Time = 1 Time = 0

38. Pull Systems- The order arrives at the end of the line and is “pulled” out of the system. WIP between the machines allows quick completion. 2.810 T.G.Gutowski 10/29/01 Pros and Cons; Pull can fill small orders quickly, but must keep inventory for all part types. Design can help here but not in all cases.

40. HP Video Results 2.810 T.G.Gutowski 10/29/01

41. HP Video Results Revisited 2.810 T.G.Gutowski 10/29/01