...Identifying Process improve Toyota Process Improvement Abstract This paper will address the identification of processed used by Toyota Corporation during the accelerator crisis. It will identify the process used and the core problems with the process. In part A of the paper the paper addresses the issues that began with sticky gas pedals, floor mats, and pedal entrapment and braking issues on some models of Toyotas vehicles. The quality of the vehicle was the issue. In part B of the paper the issue was safety and this lead to drivers dying because of safety issues. In part C of the paper Toyota has a lean process established that had no buy in from employees or Leadership which contributed to issues with their product. Toyota thought they had implemented a learn culture that consist of problem solving, teamwork, and a continuous improvement culture to sustain lean. Toyota Process Improvement Toyota is considered a global leader in the automobile business. Toyota has dominated the market with accolades from several organizations endorsing the Lexus as well as the Camry on a top ten list of best cars to own. Toyota had the market share of 12.8 percent. Toyota was based in Japan in 1933 and was introduced to the United States of American in 1957. Toyota made a name for them for producing reliable vehicles with superb quality. This paper will identify several processes for improvement that Toyota has researched, developed, or incorporated due to the crisis of the...
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...Abstract As one of the largest and most successful automakers in the world, Toyota Motor Corporation, set multiple benchmarks for quality and improvement, but faulted tremendously and faced financial crisis. In the year 2009, this company reported an annual net loss of approximately US$ 4.2 billion. In the same year, the Toyota Company was reported to have recalled more than eight million cars and trucks in the whole world. Had the company lost sight of its long-term philosophy, a key principle behind the Toyota Way? Had Toyota sacrificed quality and their historic customer focus at the expense of extreme cost reductions? Were non-family managers truly to blame for “hijacking” Toyota? This Process Identification and Improvement plan will examine process areas for improvement: Toyota Production System (TPS) integration, the company’s decision making management centralized systems, and quality of the products. Executive Summary With the global expansion occurring, the organization’s core principles became diluted. By the year 2010, Toyota faced an unprecedented crisis with both its reputation and plummeting stock prices from the effects of recalling over 10 million vehicles worldwide. Toyota put their customers at risk by failing to immediately notify the proper authorities regarding the potentially defective acceleration situation. Toyota failed to comply with the federal law in the foreign subsidiary and failed to report such safety defects to the proper government regulators...
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...Introduction Toyota Motor Corporation is a Japanese automotive manufacturer headquartered in Toyota, Aichi, Japan. In 2013 the multinational corporation consisted of 333,498 employees worldwide and, as of January 2014, is the fourteenth-largest company in the world by revenue. Toyota was the largest automobile manufacturer in 2012 (by production). In July of that year, the company reported the production of its 200-millionth vehicle. Toyota is the world's first automobile manufacturer to produce more than 10 million vehicles per year. It did so in 2012 according to OICA, and in 2013 according to company data. As of July 2014, Toyota was the largest listed company in Japan by market capitalization (worth more than twice as much as #2-ranked Softbank) and by revenue. The company was founded by Kiichiro Toyoda in 1937 as a spinoff from his father's company Toyota Industries to create automobiles. Three years earlier, in 1934, while still a department of Toyota Industries, it created its first product, the Type A engine, and, in 1936, its first passenger car, the Toyota AA. Toyota Motor Corporation produces vehicles under 5 brands, including the Toyota brand, Hino, Lexus, Ranz, and Scion. It also holds a 51.2% stake in Daihatsu, a 16.66% stake in Fuji Heavy Industries, a 5.9% stake in Isuzu, and a 0.27% stake in Tesla, as well as joint-ventures with two in China (GAC Toyota and Sichuan FAW Toyota Motor), one in India (Toyota Kirloskar), one in the Czech Republic (TPCA), along with...
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...those skills. Education, on-the-other-hand, provides general skills not specific to a particular career or job (Blanchard/Thacker, 2010). 2. Briefly describe what the organization is and what is does. This should be one or two paragraphs. Toyota was founded in 1867, by Sakichi Toyoda, with the purpose to contribute to a prosperous society with the innovation and manufacture of quality automobiles. Toyota manufactures various types of vehicles worldwide. Toyota is considered an innovative leader, and the organization is well-known for its management philosophy and the world’s first mass-market hybrids. Toyota’s vision is to create earth-friendly products for growth. Reported March 2012, Toyota conducts its business globally with 50 overseas manufacturing companies in 27 countries and regions. The automobiles are sold in more than 160 countries and regions. Toyota has a massive number of employees. There are a combined total of 11 facilities located in the United States and Canada (most in the U.S.). For example: Toyota Motor Manufacturing, West Virginia, Inc began November 1998, and this facility employs 1,069 individuals. Toyota Motor Manufacturing, Indiana, Inc. began February 1999, and this subsidiary employs 4,780 employees (Toyota Motor Corporation, 1995-2005). 3. Assess the...
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...I thought this was a good article to share as it clears some misconceptions of Toyota and their management philosophies and technology. This article was written by Stewart Anderson who is president of http://www.kaizenimprovement.ca a Toronto-based consulting and advisory firm in the areas of continuous improvement and business strategy. The tools and techniques of what is commonly called "lean manufacturing" have their origin in the Toyota Production System (TPS). While the lean movement deserves much credit for popularizing these tools and techniques, a number of misconceptions appear to have developed about how Toyota itself actually practices continuous improvement. This article looks at some of these misconceptions. Readers should note that this article is not meant to be a definitive study of Toyota, nor is it meant to supplant the excellently detailed analyses of Toyota published by Jeffrey K. Liker (The Toyota Way, McGraw-Hill, 2003), Steven J. Spear (Chasing the Rabbit, McGraw-Hill, 2008), and others. Rather, it offers the author’s own personal perspective and insights on Toyota, drawing from observation and study of Toyota production and distribution operations, supplemented by interviews with Toyota employees, managers, and suppliers held over the years. Some of the thoughts expressed below also find deeper expression and treatment in Mike Rother' excellent new book, Toyota Kata (McGraw-Hill, 2009), and readers are referred to that book for a full exposition of...
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...Operations Improvement Plan XXXXXXX MBA6022 Strategic Operations Management Address: XXXXXXXXXXXXx E-mail: xxxxx Instructor: Dr. Zhimin Huang Abstract This operation improvement plan is to help improve the internal communication process at Toyota between their employees and management. There has been a loss of ideas and knowledge, which is a complete violation of their founding principles defined in the Toyota Way. With the suggested recommendations, Toyota can once again reclaim its dominance in the world automobile market while at the same time improving their operational efficiency and quality. Table of Contents Title Page 1 Abstract 2 Table of Contents 3 Executive Summary 4 Toyota Overview 5 Toyota’s Key Challenges 5 Cost-Benefits Summary 7 Analysis of Data and Findings 8 Summary of Recommendations 11 Conclusion 11 References 13 Appendix A 14 Appendix B 15 Appendix C 16 Appendix D 17 Appendix E 18 Appendix F 19 Executive Summary The Toyota Motor Corporation has experienced numerous setbacks the past decade including lawsuits, damaged corporate reputation and eroding consumer confidence. Although many different processes can be to blame for this, ultimately it is Toyota’s upper management that has to be held accountable for the decisions made. One of the contributing factors...
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...EXECUTIVE SUMMARY Operations Management plays a vital role in all the forms of organisation. Lack of operations management can lead to the failure of the business. In the following report we discuss the world’s largest automobile industry the Toyota Manufacturing Company and also some of the various principles with description and are useful in the operations management such as Just in Time, kaizen, vertical Integration, Toyota Production system and the Vertical Integration. These principles play a major role in the effective production and operations of Toyota as well as most of the other organisations. Let us now discuss the principles of operations management beginning with the history and background of Toyota. INTRODUCTION Japan is the world’s second largest automobile nation with 73 million vehicles on the road. Toyota is a Japanese company founded and formed by Kiichiro Toyoda in the year 1936. He was given a full strong support by his father Sakichi Toyoda an industrialist who use to invent Toyota Model G automatic loom. In the year 1937 the Toyota Motor Company Ltd was established. Since then it grew rapidly in the recent years. The success of the company was based on the principles of innovation and both for its products and the processes to make the product. At the start of the company the aim was to produce reliable and efficient cars in Japan. The company was very well accepted by the people and since then the company touched the heights...
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...Toyota | | Lean Changed the Auto Industry Introduction In order for any business to succeed, the business needs a strong leader. Taiichi Ohno, Toyota’s businessperson and engineer, led the implementation of Lean during the 1950’s and 1960’s. Prior to Ohno leadership, he learned the auto industry from Toyota founder Kicchiro Toyoda. In the post World War II recession, Toyota was near bankruptcy, and workers went on strike. In 1950, Toyota began to restructure their company and settle the strike. In the settlement, Toyoda and other top executives resigned (1). After the strike, Toyota utilized Lean to save their company from bankruptcy. In the process of developing Lean, Toyota became a leader in the auto industry. They sold 10.23 million vehicles in 2014, which ranked them number one in global sales (15). The report show and pinpointed how Toyota developed and used Lean Accounting and Manufacturing to become the number one seller of automobiles. The Development of Toyota Production System Taiichi Ohno, the primary architect, and his consultant Shigeo Shingo designed the Toyota Production System (TPS). The TPS emphasizes on avoiding any waste. Toyota lacked resources to invest in new production equipment or carry inventory. The TPS concept is the anti economies of scale. Cho and Taiichi preached this concept to their employees as they transformed into a lean organization. They could only afford to purchase the exact amount of materials needed to produce...
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...why it is vital for any kind of business or service organization. Quality management emphasis on the ways those are used in improving and controlling quality. Quality control management intended to identify and prevent products those contains faults from reaching customers. Since the foundation of Toyota, it has been successfully carried out its quality control activities in a steadfast manner and it results in the top ratings from their customers. Toyota uses some key principles to maintain their quality control management system and those principles are such as, 'Customer First', 'Quality First' Go & see at the scene', and these principles were established and imposed when the Toyota company was founded. TASK 1 Examine the concepts of quality in Toyota and discuss what drive Toyota to meet the customer requirements and quality. The improvement of products and work quality in the production and distribution by listening to "Voice of the customer" is the core concept behind Toyota's quality control activities. When there was a merger between the ‘Toyota Motor Co., Ltd’ and ‘Toyota Motor Sales Co. Ltd.’ in 1982 in order to forming the new ‘Toyota Motor Corporation’, and for the customer’s assistance some operations that had been carried out by various departments then to satisfy customers were unified in order to establishing the ‘Customer Relations Division’. The Toyota Company tries it’s best to ensure the enhanced satisfaction to their customers by delivering "Voice of...
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...vital for any kind of business or service organization. Quality management emphasis on the ways those are used in improving and controlling quality. Quality control management intended to identify and prevent products those contains faults from reaching customers. Since the foundation of Toyota, it has been successfully carried out its quality control activities in a steadfast manner and it results in the top ratings from their customers. Toyota uses some key principles to maintain their quality control management system and those principles are such as, 'Customer First', 'Quality First' Go & see at the scene', and these principles were established and imposed when the Toyota company was founded. TASK 1 Concepts of quality of Toyota Automobile Company and discussion over ‘what drives Toyota to meet their customer requirements and quality.’ The improvement of products and work quality in the production and distribution by listening to "Voice of the customer" is the core concept behind Toyota's quality control activities. When there was a merger between the ‘Toyota Motor Co., Ltd’ and ‘Toyota Motor Sales Co. Ltd.’ in 1982 in order to forming the new ‘Toyota Motor Corporation’, and for the customer’s assistance some operations that had been carried out by various departments then to satisfy customers were unified in order to establishing the ‘Customer Relations Division’. The Toyota Company tries it’s best to ensure the enhanced satisfaction to their customers by delivering...
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...TOYOTA PRODUCTION SYSTEM BASIC HANDBOOK TABLE OF CONTENTS Introduction & History of the Toyota Production System ........................ 3 Goals of the Toyota Production System. ................................................. 4 TPS Model Overview............................................................................5-6 Respect for People .................................................................................. 7 Focus Areas of TPS ................................................................................ 8 Eliminating Waste..........................................................................9-10 Quality .........................................................................................11-12 Cost. ................................................................................................. 13 Productivity....................................................................................... 14 Safety & Morale ................................................................................ 15 Jidoka . .............................................................................................16-18 Standardization……………………………………………………………….19 Just in Time ........................................................................................... 20 Pull Production………………………………………………………………..21 Kanban……………………………………………………………………..22-23 Level Production...............................................................................
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...TOYOTA PRODUCTION SYSTEM BASIC HANDBOOK TABLE OF CONTENTS Introduction & History of the Toyota Production System ........................ 3 Goals of the Toyota Production System. ................................................. 4 TPS Model Overview............................................................................5-6 Respect for People .................................................................................. 7 Focus Areas of TPS ................................................................................ 8 Eliminating Waste..........................................................................9-10 Quality .........................................................................................11-12 Cost. ................................................................................................. 13 Productivity....................................................................................... 14 Safety & Morale ................................................................................ 15 Jidoka . .............................................................................................16-18 Standardization……………………………………………………………….19 Just in Time ........................................................................................... 20 Pull Production………………………………………………………………..21 Kanban……………………………………………………………………..22-23 Level Production.................................................................................... 24 Takt...
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...Toyota Organizational Culture Toyota is the world leader in manufacture of motor vehicles. Toyota has branches all over the world, and in almost all states in the United States. The three levels of culture which include in Toyota organization are artifacts, espoused beliefs and values, and basic underlying assumptions. The major aspects of organizational culture within Toyota include leadership and motivation (structures and processes), team work and communication (ideals, goals and values), and conflict resolution (taken-for-granted beliefs). According to Schein, “artifacts include the visible products of the group, such as the visible and feelable structures and processes” (Schein, 2010). Toyota leadership style is democratic, and it proven to be effective within Toyota. Toyota let their employees involved in decision making process, especially when the decisions affect themselves. At Toyota, employees are independence and there are minimal supervisions from the management. By doing this, it enable the employees to be innovative and work without interference. “Toyota has an elaborate employee participation and empowerment related system that uses creative suggestion program and quality improvement system using quality control circles” (Nayebpour, 2007). When employees make a mistake, the upper management advises employees to take it as a learning experience instead of award punitive measures. The upper managements always available to the employees at all times to solve their...
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...financials, size, and global presence. Toyota Motor Corporation was founded in 1919 by the famous Japanese inventor, Saki chi Toyoda. Its primary business is manufacturing and selling automobiles. With operations in the U.S. for the past 50 years, Toyota is one of the most well known automobile manufacturers in the world. In fact, it is the largest automobile manufacturer in the world, producing over 7 million units in the last financial year. (Liker, 2008) During this time it reported a profit of over $5 billion dollars. It is a multinational corporation with its corporate office located in Toyota City, Aichi, Japan. Toyota currently employs roughly 310,000 people around the world. (2010) The Toyota Way and the Toyota Production system are what make up Toyota’s DNA. The Toyota Way can be summarized two ways: continuous improvement and respect for people. (Liker & Hoseus, 2008) Continuous improvement is translated as Kaizen which is huge in the Toyota culture where this means challenge everything. (2008) Toyota is also responsible for the invention of the term “lean production” sometimes called the Toyota Production System or TPS. (Liker, 2005, p. 115) This invention has triggered a global transformation in just about every industry to Toyota’s manufacturing and supply chain philosophy and methods for over a decade. The company has won awards for being the best in class by both its peers and competitors throughout the world. Toyota automobiles have consistently been at...
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...Introduced by Toyota, Lean is more than just a tool, but a philosophy that needs to be adopted and incorporated into the culture of the organization. It is very important that the organization can see that leadership have bought in to the approach and are willing to support Lean. Numerous examples exist that demonstrate failed attempts at implementing Lean. It is important that organizations appreciate that they cannot simply wake up one day and choose to introduce Lean. It took Toyota many years to develop their culture into one of continuous improvement. For organizations that are new to Lean, the effort required will be significant in order to realize the true value associated with Lean principles. Poor planning will almost certainly result in disappointment and leave a strong negative association with any future Lean attempts along with a big investment with little to no return. With a focus on continuous improvement and continuous flow, manufacturing based on pull rather than push demand will assist organizations in becoming Lean. While Lean is a long journey, it can be one that returns significant value to an organization. What follows is a view of the history of Lean, some of the tools such as Value Stream Mapping, Kaizen, etc, along with the expected benefits, potential barriers, critical success factors, and a quick view of Lean at Suncor. Table of Contents 1.1. Introduction 4 1.2. Concepts, Theories, Tools and Techniques 5 1.2.1. The Toyota Production...
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