Oct 28 2015
Akio Toyoda’s aggressive reboot | Automotive News
Akio Toyoda is rolling out an aggressive overhaul of Toyota Motor Corp. that aims to improve everything from manufacturing and product planning to design and human resources.
Sourced through Scoop.it from: www.autonews.com
See on Scoop.it – lean manufacturing
October 28, 2015 @ 3:12 pm
Toyota may be rebooting their activities & creating a new style of factory, but I think this is an extension of, & a more aggressive application of the basic principles that have always driven their activities. —
When Lean thinking was extracted from the TPS, it lost some clarity of these basic principles.–
The main performance goals for TPS are to give the customer & society;
What they want. (The best P, S, & E available in your industry. Product, service & experience). —
In the quantity they want, without defects. (Any multiple of one. One piece flow facilitates this capability. Jidoka & Poka- yoke will ensure zero defects). –
Delivered when they want it. (Just in time to suit their needs. Takt time is the driver). —
These values must also be continuously improving faster than any existing or future competitor. —
(The new ‘Toyota New Global Architecture’ with enable designs to be customised to specifically suit local market needs. 75% of the investment saving from TNGA will be invested into ‘making even better cars’. TNGA will achieve significant reductions in new model introduction times. The new factories can adjust output to suit a 50% change in demand within a single shift.) —
There are three main activity goal areas in TPS to achieve this. They are called the 3 R’s. —
The first ‘R’ is Resources. The goal in this area is to achieve the three performance goals using the minimum ‘Resources’ (i.e. materials – machinery – methods – movement – minutes – manpower – money). Anything above the minimum resources required to produce the product, service & experiences that will delight the customer is defined as waste, & is a target for removal. This is one the main areas of focus for TPS & lean activities – Waste elimination. What cannot be removed should then be seen as a target to be continuously improved. The first rule in this area is; remove it before you try to improve it. —
(The new ‘simple and slim’ factory design takes waste elimination to a new level. They will be 25% smaller, cost less to build, use much less energy and reduce emissions. Other features are listed below.)
The second ‘R’ has been largely missed by the lean movement; this is Resourcefulness.
The goal in this area is to release the ‘Resourcefulness’ (talent, creativity & enthusiasm) of all our people to achieve the first three goals. This ability must also drive the waste elimination & continuous improvement process throughout your organisation & down through your supply chain. A key rule in this area is; sustain the gains, maintain the change. —
(This Toyota programme is a wonderful example of the resourcefulness of their people. From the design of the new smaller style of factory with their no ‘hanging no digging’ features & surface mounted conveyors. To new paint plants that are smaller, 40% cheaper to build and use 40% less energy. Equipment that reduces pre-heat times on sheet metal parts from 5 mins to 15 seconds & now can preheat one piece. To Laser Screw Welding that can halve welding times.) —
The third ‘R’ is ‘Respect’. Again this was missed by the original lean thinkers. From my own experience we must see ‘RESPECT’ as the password that gives access to the file that contains our people’s total ability (talent, creativity & enthusiasm). Without the correct password, access will not be possible. This is one of the key bonding elements between managers & their people. The key rule in this area is; Star managers must make their people shine. —
Respect should not be seen as a ‘soft-side’ subject. A lot is given & a lot is will be returned. —
When you apply this thinking not only to your external & internal customer contact areas, but also down your supply chain, you will start to understand where & how Toyota’s amazing performance & competitive advantage is created. The new developments at Toyota illustrate the power & their mastery of the 3 R’s.