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

ToyotaIndiana

ForecastDailyOrders

Production Control

MRP

Forecast

DailyOrders

Tube Bending Stamping Purchase Parts Spun Res.

2 Days 5 Days 2 Days

Batch

Max: 3 Boxes

Outside Processes

MRP

Process Process Process

Suppliers

Purchase Parts,Steel, Raw Pipe

Pipe 2 Days Steel 2 Days

Coils

5 X Week 1 Days Pipe 2 days

94 Secs

5 days

65 Secs.

1.5 Days

Production Lead Time

8.5 Days

Processing Time @

159 Secs.

2 Production

Shift

775 Vehiclesper day

8 X Daily

C/T - 30 Secs.C/O - 15 Mins. C/T - 2 Secs.C/O - 30 Mins. C/T - 62 Secs.C/O - 0

Totes FIFO

Coil

Purch.Parts

35

35

35

Assembly &SecondaryAssembly

ShippingStaging

X 9 Operators

C/T - 65 Secs.C/O - 15 Mins.Scrap - .75%Overtime -<1Hour/Day

35

35

Daily

Order

Figure 19-8.

Toyota 500N center cell future state fourth quarter 2004