...BY AMY NINC The Toyota story has been intensively researched and painstakingly documented, yet what really happens inside the company remains a mystery. Here's new insight into the unspoken rules that give Toyota its competitive edge. Decoding the DNA of the Toyota Production System by Steven Spear and H. Kent Bowen long been hailed as the source of Toyota's outstanding performance as a manufacturer. The system's distinctive practices -its kanhan cards and quahty circles, for instance - have been widely introduced elsewhere. Indeed, following their own internal efforts to henchmark the world's best manufacturing companies, GM, Ford, and Chrysler have independently created major initiatives to develop Toyota-like production systems. Companies that have tried to adopt the system can be found in fields as diverse as aerospace, consumer products, metals processing, and industrial products. What's curious is that few manufacturers have managed to imitate Toyota successfully-even though the company has been extraordinarily open about its practices. Hundreds of thousands of executives from thousands of businesses have toured Toyota's plants in Japan and the United States. Frustrated by their inability to replicate Toyota's performance, many visitors assume that the secret of Toyota's success must lie in its cultural roots. But that's just not the case. Other Japanese companies, such as Nissan and Honda, have fallen short of Toyota's standards, and Toyota has successfully introduced...
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...Toyota Production System (Adapted from Slack, et al. 2006) Seen as the leading practitioner and the main originator of the lean approach, the Toyota Motor Company has progressively synchronised all its processes simultaneously to give high quality, fast throughput and exceptional productivity. It has done this by developing a set of practices that has largely shaped what we now call ‘lean’ or ‘just-in-time’ but which Toyota calls the Toyota Production System (TPS). The TPS has two themes, ‘just-in-time’ and ‘jidoka’.’Just-in-time’ is defined as the rapid and coordinated movement of parts throughout the production system and supply network to meet customer demand. It is operationalised by means of heijunka (levelling and smoothing the flow of items), kanban (signalling to the preceding process that more parts are needed), and nagare (laying out processes to achieve smoother flow of parts throughout the production process). Jidoka is described as ‘humanizing the interface between operator and machine’. Toyota’s philosophy is that the machine is there to serve the operator’s purpose. The operator should be left free to exercise his or her judgement. Jidoka is operationalised by means of fail-safe (or machine jidoka), line-stop authority (or human jidoka), and visual control (at-a-glance status of production processes and visibility of process standards). Toyota believes that both just-in-time and jidoka should be applied ruthlessly to the elimination of waste, where...
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...Syllabus for ESD.60 Summer 2015 Session | | Session Date | Assignment Due* | 1&2 | Introduction | 6/19/15 | 1 | 3&4 | Session 3: Implementing TPS at Brownfield Site, Decoding the DNA of a Toyota Production SystemSession 4: System Design & Problem solving | 6/26/15 | 2-4 | 5&6 | Session 5: Pratt and Whitney: Engineering Standard WorkSession 6 overflow: Salt Lake Olympic Committee | 7/10/15 | 5&6 | 7&8 | Session 7: Designing products and processes & How complex systems failSession 8: Repairing a broken system | 7/17/15 | 7&8 | 9&10 | Session 9: Madison Avenue: Digital Media ServicesSession 10: Building a base for growth | 7/23/15 | 9&10 (Graded Assignment Due: Madison Avenue in teams of 3) | 11&12 | Session 11: Learning to Lead at ToyotaSession 12: Developing Capabilities | 7/31/15 | 11&12 | 13&14 | Session 13 &14: Competing at speed in a fast changing world: The structure and problem solving dynamics of “gap filling” organizations | 8/4/15(1:30-4:30) | 13&14 | 15&16 | Session 15: Front line worker interviewSession 16: Learning in context, idiosyncrasies, and getting close enough to actually learn | 8/14/15 | 15&16 (Graded Assignment Due: Front line worker interview) | 17&18 | Session 17: Managing Complex Systems for SuccessSession 18: Final session & wrap-up | 8/18/15 | 17&18 (Graded Assignment: Final Assignment) | *The specifics of each assignment are posted on stellar. We encourage...
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...Toyota Production System Da Wikipedia, l'enciclopedia libera. IMPIANTI INDUSTRIALI Il Toyota Production System, detto anche, in alcune pubblicazioni accademiche, Toyotismo, è un metodo di organizzazione della produzione derivato da una filosofia diversa e per alcuni aspetti alternativa alla produzione di massa, ovvero alla produzione in serie e spesso su larga scala basata sulla catena di montaggio di Henry Ford. Produzione industriale Progettazione di prodotto Design - DFX CAD - CAE Progettazione di processo Processo di produzione industriale Meccatronica - CNC - Robot industriale CAM - PLC - CAPP Il nome deriva dal fatto che essa è stata inventata negli anni 1940-1950 presso la Toyota, da Sakichi Toyoda, Kiichiro Toyoda, ed in particolare dal Progettazione di sistema giovane ingegnere Taiichi Ohno. Alla base del TPS si trova l'idea di 'fare di più con meno', cioè Sistema di produzione - GT di utilizzare le (poche) risorse disponibili nel modo Taylorismo - Fordismo - Catena di montaggio - UTE più produttivo possibile con l'obiettivo di JIT - Toyotismo - Produzione snella incrementare drasticamente la produttività della Automazione - Fabbrica automatica - FMS fabbrica. La Toyota, nell'immediato dopo-guerra, CIM - MRP - ERP - TQM si trovava in condizioni gravissime di mancanza di risorse, come peraltro gran parte dell'industria del Giappone, uscito sconfitto e stremato da una guerra devastante. Esso si basa su 5 principi puntando su un concetto apparentemente semplice:...
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...Planning/Assessing Production for Toyota North America Executive Summary The Toyota Production System (TPS) is an integrated approach to work design that was developed and implemented by Toyota. The key characteristic of this system is that it takes into account the interactions that occur between technology and the human counterparts, which include employees, suppliers and customers. At its core, the TPS is a direct reflection of Toyota's management style and practices. The following summary will examine the TPS, including key terms that form the framework for the TPS, a comparison of the two most optimal locations, through the use of the weighted scoring model, for the selection of the North American plant which will be responsible for the production of the new Lexus RX330 line, an exploration of the production capacities through the use of decision trees, and provide an overall assessment of Toyota's current production strategy. I. Critical Assessment of the Toyota Production System (TPS) Today TPS Terms 1. Genchi Genbutsu- In essence means one has to observe a problem to fully understand it. One cannot simply rely on their second hand experience and second hand accounts of their experiences. For example, during hurricane Katrina, the Federal Emergency Management Agency (FEMA) initially heard second hand accounts of the damage and devastation experienced by residents of Katrina. FEMA was unable to thoroughly assess the state of emergency and issues 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 System...
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...Citation: Netland, T. H. & Aspelund, A. (2013) Company-specific production systems and competitive advantage: A resource-based view on the Volvo Production System. International Journal of Operations & Production Management, Vol. 33, Iss. 11/12 Post-print. This is an Author's Original Manuscript of an article accepted for publication in the International Journal of Operations & Production Management, Vol. 33, Iss. 12. Forthcoming. Company-specific Production Systems and Competitive Advantage: A resource-based view on the Volvo Production System Torbjørn H. Netland1, 2 and Arild Aspelund1 1 Department of Industrial Economics and Technology Management, NTNU 2 McDonough School of Business, Georgetown University Abstract Purpose: In order to improve competitiveness on a global scale, multinational enterprises increasingly develop a company-specific Production System (XPS) and deploy it in their worldwide operations. An XPS is synonymous with a tailored corporate-wide improvement programme. The purpose of this paper is to explore the circumstances under which an XPS can provide a competitive advantage. Methodology: We use an explorative case study methodology to investigate the link between the establishment of an XPS and competitive advantage. Specifically we investigate the part of the Volvo Group’s globally implemented Volvo Production System (VPS) that aim to improve the manufacturing processes worldwide. Due to its historical trajectories, Volvo ...
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...Queen’s University Belfast Queen’s University Management School. MGT2005 OPERATIONS MANAGEMENT Semester 2, 2012 “You don’t have to change. . . Survival is not mandatory.” (Professor William E. Deming) Course Co-ordinator: Dr Yu Xiong Introduction to Operations Management Operations Management (OM) is a functional field of management encompassing the design, operation and improvement of the processes and systems employed in the creation and delivery of an organisation's products and services. Essentially, operations management is concerned with explaining how factories and services work. Managing operations well requires both strategic and tactical skills and is critical to every type of organization, for it is only through effective and efficient utilization of resources that an organization can be successful in the long run. A few common threads pervade the material we cover in this course: First, decision making in operations is highly context dependent. Recognising this is half the battle in managing an operation. The variety of operational contexts obscures the link between particular operational decisions and overall firm profitability. Making this link transparent is essential to making better operational decisions. Variability exists in any operation, and this variability needs to be managed Integration, both across functional areas within a firm, and across firms in the value creation and delivery network, is crucial for superior firm performance...
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...e-mail: Edward.Anderson@mccombs.utexas.edu Office Hours: By appointment Mail Box: IROM Dept., CBA 5.202 Fax: 471-0587 Web: All web material is at www.EdAnderson.org or can be reached via Blackboard. Personal/Research Web: www.EdAnderson.org COURSE DESCRIPTION Operations Management involves those aspects of your firm that provide the goods or services in your firm’s value proposition to your targeted market. As such, operations will be decisive in determining the long-term viability of your firm’s business model. This fact has become even clearer in recent years as competition has increased with more globalization and improved information technology. By integrating operations successfully into the their business models, firms such as Dell, Toyota, and Wal-Mart have shown that good operations make good business sense. The objective of this course is to provide you with an understanding of Operations Management and the role that it plays within an organization. By the end of the course, you should have developed an appreciation for the challenges in providing world-class products and services and the ability to use some analytical tools and conceptual frameworks to guide your thinking about operations. It is important to realize that much operations consists of the systematic design, operation, control and improvement of business processes. Accordingly, you should leave this course able to: • • • • • Integrate operational perspectives into a successful business model; Analyze...
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... use of kaizen and quality circles which empower the workforce, are some of the various keys to a successful lean implementation in a textile industry. Keywords:Project manegement; lean manufacturing; agile manufacturing; value stream mapping; VSM; supply chain management. 1 Introduction What Is a Project Manager? SECTION 1: INTRODUCTION TO PROJECT MANAGEMENT Project management is the art of matching a project's goals, tasks, and resources to accomplish a goal as needed. We say "as needed" because one has limited time, money, and resources (human and machinery) with which to accomplish a goal. One can think of a project as a process. Figure 1 shows this process as a simplified block diagram. Figure 1: Simple Project Management System The process involves inputs and outputs. Successful projects "do the right things, with the right tools, and in the right way". SECTION 2: STAGES OF A PROJECT AND HOW TO COMPLETE THEM Stage 1: Defining the goals of the project: Garbage in equals garbage out. If you do not start a project with the correct goal(s), it is not likely you will accomplish the goal(s). This must be a team activity to ensure that everyone is given the opportunity to contribute and "buy-in" to what is going...
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...fortunate that I had Mr/Ms Xxxx as my project leader and cannot thank him/her more for the unstinted encouragement I had received throughout this period. If his/her suggestions that resulted in necessary and timely course corrections were not there, I doubt very much whether this project would have at all seen the light of the day, let alone being successfully completed within the deadline. ABSTRACT The word that is most significant in Lean Manufacturing process is ‘lean’ which literally means a body or a system that does not have any unnecessary or avoidable flab or float. Such flab or float exists in manufacturing systems and are manifested through unnecessary or nil value movements or costs that do not add to the final worth of the finished product but increase total cost of production. The requirement of such a stringent approach to production process arose immediately after the Second World War especially in Japan which was facing a critical situation with most of its production facilities destroyed by Allied bombing and social infrastructure in total shambles following its ignominious defeat. The...
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...„ Project Management Institute, 2002. Used with permission. The underlying theory of project management is obsolete1 Lauri Koskela, VTT Technical Research Centre of Finland Gregory Howell, Lean Construction Institute Abstract In prior literature, it has been generally seen that there is no explicit theory of project management. We contend that it is possible to precisely point out the underlying theoretical foundation of project management as espoused in the PMBOK Guide by PMI and mostly applied in practice. This foundation can be divided into a theory of project and a theory of management. We link theories to the body of knowledge by comparing prescriptions derived from theory to prescriptions presented in the PMBOK. Secondly, we show, by a comparison to competing theories and by an analysis of anomalies (deviations from assumptions or outcomes as implied in the body of knowledge) observed in project management practice, that this foundation is obsolete and has to be substituted by a wider and more powerful theoretical foundation. Introduction In a recent report on the future of project management and its professionals (Project Management Institute 1999), several global trends, such as technological advancements and the accelerated global change, were identified, in relation to which project management can take a leading role in facilitating and enabling the changes involved. The report also contains, in an appendix, a concise study on the development of bodies ...
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...Systems and Operations Management Mercedes Benz Analysis of the competitiveness of operations management Abhijeet Ghosh, A4060514, MBA Intake 14 (Group B) London School of Business and Finance Table of Content Executive Summary & Introduction 3 Product and Services 3 Task 1: Operations Management 4 Operations Strategy 4 Process Design 4 Body Shop 5 Paint Shop 6 Assembly 7 Just in Time 8 Quality Management 8 Innovation and Improvement 9 Supply Chain Management 10 Task 2: Integration of Information system 12 Business Integration Server 13 Task 3: Job Design 14 Lean Manufacturing 14 Conclusion 15 Appendix 16 Reference 18 Executive Summary and Introduction Mercedes-Benz is a division of the German manufacturer Daimler AG, and the brand is used for automobiles, buses, coaches, and trucks. Mercedes-Benz is headquartered in Stuttgart, Baden-Württemberg, Germany. The name first appeared in 1926 under Daimler-Benz but traces its origins to Daimler's 1901 Mercedes and to Karl Benz's 1886 Benz Patent Motor-wagen, widely regarded as the first automobile. Part of Daimler AG, Mercedes-Benz USA (MBUSA) is responsible for the distribution and marketing of Mercedes-Benz, May Bach, smart, and Sprinter products in the United States. In 2011, the company sold 264,460 passenger vehicles in the US, representing 17.5% year-over-year growth, in addition to 16,577 Sprinters. Although MBUSA was founded in 1965, importation of Mercedes-Benz vehicles actually began...
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...McKinsey Global Institute May 2013 Disruptive technologies: Advances that will transform life, business, and the global economy The McKinsey Global Institute The McKinsey Global Institute (MGI), the business and economics research arm of McKinsey & Company, was established in 1990 to develop a deeper understanding of the evolving global economy. Our goal is to provide leaders in the commercial, public, and social sectors with the facts and insights on which to base management and policy decisions. MGI research combines the disciplines of economics and management, employing the analytical tools of economics with the insights of business leaders. Our “micro-to-macro” methodology examines microeconomic industry trends to better understand the broad macroeconomic forces affecting business strategy and public policy. MGI’s in-depth reports have covered more than 20 countries and 30 industries. Current research focuses on four themes: productivity and growth, the evolution of global financial markets, the economic impact of technology and innovation, and urbanization. Recent reports have assessed job creation, resource productivity, cities of the future, and the impact of the Internet. MGI is led by McKinsey & Company directors Richard Dobbs and James Manyika. Yougang Chen, Michael Chui, Susan Lund, and Jaana Remes serve as MGI principals. Project teams are led by a group of senior fellows and include consultants from McKinsey’s offices around the world. These teams draw...
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...Surgery (Chapter 4) ● How to Make Money in the Vacuum Tube Business (Chapter 5) ● The Evolution of Strategy at Procter & Gamble (Chapter 6) ● Diversification at 3M: Leveraging Technology (Chapter 7) ● News Corp’s Successful Acquisition Strategy (Chapter 8) ● How to Flatten and Decentralize Structure (Chapter 9) Practicing Strategic Management Application-based activities intended to get your students thinking beyond the book. Small-Group Exercises Short experiential exercises that ask students to coordinate and collaborate on group work focused on an aspect of strategic management. Exploring the Web Internet exercises that require students to explore company websites and answer chapter-related questions. Designing a Planning System (Chapter 1) Evaluating Stakeholder Claims (Chapter 2) Competing with Microsoft (Chapter 3) Analyzing Competitive Advantage (Chapter 4) How to Keep the Salsa Hot (Chapter 5) Developing a Global Strategy (Chapter 6) Comparing Vertical Integration Strategies (Chapter 7) ● Identifying News Corp’s Strategies (Chapter 8) ● Speeding Up Product Development (Chapter 9) ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ●...
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