Toyota Way Fieldbook : A Practical Guide for Implementing Toyota's 4Ps

Pipe 2 Days

4 Days

Steel 2 Days

5 Days

Purchase4 Days

4 Days

4 Days

1.5 Days

4 days

5 days

17 days192 Secs.

C/T - 30 Secs.C/O - 15 Mins. C/T - 2 Secs.C/O - 1 Hour C/O - 0

C/T - 62 Secs.

C/T - 52 Secs.C/O - 1 HourScrap - 4% of Sales

Overtime - 4 Hrs. per

day

2 Separate Plants

2 Shifts

CustomerToyota

ForecastDailyOrders

Production Control

MRP

Forecast

2.5

X / Week

8 X Daily Shipping

Suppliers

Purchase, Steel.

Pipe

Production Supervison

Daily ShipSchedule

DailyOrders

5 X Week

Tube BendingProcess Spun Res.Process

IntroduceWeekly Kanban

SupplierPull

94 Secs

Add press toF/B delivery

route

Implementtimed Materialdeliveries Create containerKanban

Weekly Schedule

AssemblyX 16 Opers.

Lean Bascis-EPEI-Line Balance-S/W-Layout

LevelSchedulePacesetter

Scrap -Six Sigma

SMED Assy.C.over

52 Secs.

5 Days

48 Secs.

3 Days

Target CellReduce LeadTime

C/T - 48 Secs.

Secondary Assy.

Bolt- UpProcess

Balance Workto eliminatesecondaryassembly

Weekly Schedule

Purchase

Outside Sources

PressProcess

Figure 19-7.

Toyota 500N center cell current state second quarter 2004