...providing us with all necessary facilities. We are thankful to him, for his expert advice and help which has always been source of inspiration for us. Above all, we owe everything to the Almighty and well-wishers for their valuable contribution and insights. However, we have taken utmost care in preparing this project report, mistakes would have crept though. (12010121196) Ms. N AMULYA REDDY (12010121213) Ms. NIKITA SINGHANIA (12010121276) Mr. REUBEN JOSEPH (12010121032) Mr. AMIT KUMAR JENA (12010121057) Ms. ARPITA DEB (12010121316) Ms. SAYONEE DATTA 1 Topic. Case Summary Q1: Toyota's revolutionary lean production Q2: Compare and contrast the arm's length relationships Q3: Development of Toyota's revolutionary "lean production system" Q4: Toyota enter into the NUMMI Q5: Toyota's subsequent expansion Q6: Role of national culture in shaping Toyota's lean production system Q7: Toyota is becoming more of a global corporation Page No. 03 05 07 08 09 10 12 13 2 SUMMARY Background Toyota is a multinational automobile manufacturing corporation headquartered in Japan. The company was founded by Kiichiro Toyoda in 1937 as a spin-off from...
Words: 4569 - Pages: 19
...leader in manufacturing activity, providing employment to one in seven people, either directly or indirectly. Hailed as the ‘industry of industries’ by the Management Specialist, Peter Drucker, the automobile industry (US) set standards in manufacturing activity by contributing mass production techniques during early 1910s. The Japanese soon followed by offering lean production techniques in the 1970s. Riding high on economical revival in many developing countries in Asia and Europe, the industry’s global output touched 64.6 million vehicles in 2005. But with a downward slide in market share, the Big Three was fast losing their dominant position to Toyota, Honda, and Nissan, thereby setting the ground for the emergence of New Six. Meanwhile UK, served as the single largest customer for European auto-makers. Japanese players were the leaders in the light vehicle market and hybrid market. China and India attracted the attention of global auto-makers, vying for setting up a cost-effective export base for meeting the demand from Asian markets. Despite government controls, Chinese market boasted of sales of more than 2.7 million commercial vehicles in 2004. With reports of highest growth in mobility in the world at 3% per annum, further surge in demand was anticipated from Chinese market. A booming economy and a low interest regime helped India to make its mark in the automobile sector in 2004, with sales figures exceeding more than 1 million in the passenger car segment for the first...
Words: 12500 - Pages: 50
...White Paper Lean Manufacturing Lean Manufacturing Table of Contents Executive Summary.......................................................................................................................................................................................2 Introduction .......................................................................................................................................................................................................4 Lean Manufacturing—So What? .................................................................................................................................................4 Objectives .................................................................................................................................................................................................6 The Manufacturing Challenge .................................................................................................................................................................7 Globalization and Competitive Pressure ................................................................................................................................7 Mass Production to Mass Customization ...............................................................................................................................7 Shortening Product Life Cycles........................................................................
Words: 8925 - Pages: 36
...Just-in-Time Production and Lean Manufacturing Keller Graduate School of Management Spring Semester, May 2010 Session GM588: Managing Quality (online) Instructor: Robert Lee 5 June 2010 Table of Contents I. Introduction 3 What is it? 3 Background 5 History 7 II. Literature Review 9 Significance in Practice 9 JIT and Lean Thought Processes 10 JIT & Lean Thinking – General Principles 10 Advantages/Benefits of JIT/lean 10 Major Advantages/Benefits of JIT 11 Major Advantages/Benefits of Lean Productions 11 Relevance of JIT/lean in Today’s Businesses 11 Mistakes of Implementation 13 Additional Challenges 13 III. Demonstrations and Applications in the Business World 16 Survival Strategy for Business 16 List of Companies that use JIT/lean production techniques 18 Best Practices & Successful Implementation 18 IV. Conclusion and Reflection 20 References 22 Introduction * What is it? Just-in-Time (JIT) production is a set of principles applied to manufacturing and inventory to control the purchase of materials to produce units on a need-basis. JIT is set on the philosophy that controlling raw materials purchased for production to bring them into the manufacturing process as they are needed leads to cost savings and production efficiencies. JIT focuses on realizing that holding little or no inventory has economic and quality values for the organization. Manufactures receive raw materials from suppliers only to be used immediately in production, using...
Words: 4589 - Pages: 19
...interchangeability and the introduction of the moving assembly line in 1913. These concepts were taken even further by Alfred Sloan of General Motors. After combining Ford’s factory policies and Sloan’s marketing techniques we get mass production in its final mature form. However after decades of churning out millions of vehicles per year, Eiji Toyoda found faults in the system considered by many as the ultimate production system. He along with his production genius TaiichiOhno, soon developed the system which would once again revolutionize the automobile production system as the world would see it. By applying lean manufacturing in their home country of Japan, they and their company, Toyota, they were able to match the production volumes of GM with a workforce of almost half. Now, around the turn of the millennium there is considerable research going on in the field of flexible and reconfigurable manufacturing systems to find “The Next Big Thing” in manufacturing systems. In the subsequent paper I will try to outline the developments of mass production, lean production and FMS & RMS i.e. the past, present and future of automobile manufacturing. Past – Mass Production Before understanding just how much effective mass production was, we need to know the production system...
Words: 3288 - Pages: 14
...dynamic, manifesting a number of feedback loops. For example, institutional incentives stimulate technological discoveries, which, in turn, enable firms to pursue resourcesubstitution policies, thereby modifying production possibilities. During the period after the second world war, at least through the 1980s, Japan and Japanese firms seemed to have successfully adapted themselves to the competitive forces of emerging global markets. In spite of a poor natural resource base, a dramatically altered set of institutional arrangements (a combination of democratic government, free-markets and the rule of law) created a propitious atmosphere for innovative behaviour. Nowhere were adaptations to this altered environment more apparent than in the Japanese automobile and semiconductor industries and no firm was more successful, admired and emulated than Toyota Motor Corporation. Indicative of these changes is a Fortune magazine article, published several years ago, which provided a popular assessment of the successes of Toyota. It reported that Toyota was named the most admired motor vehicle manufacturer in the world in 1997, 1998 and 1999 as well as being ranked 11th among the world’s most admired companies in 1998 alongside firms that have been recognised for setting world-class standards of performance in a wide variety of industrial groups (General Electric, Coca-Cola, Microsoft, Disney and so on). More recently, Fortune ranked Toyota as top automobile...
Words: 5964 - Pages: 24
...SCHOOL OF BUSINESS University of Aarhus MASTER THESIS Challenges in Lean implementation Successful transformation towards Lean enterprise Ana Valentinova Kovacheva Supervisor: Ana Luiza Lara De Araújo MSc in Strategy, Organization and Leadership January 2010, Aarhus 2 Abstract The paper is based on a systematic literature review that examines how the implementation of Lean could bring value to the organization processes and contribute for achieving an operational excellence. Different organizational factors which have importance in the implementation process, are thoroughly examined. Key success factors that enhance the implementation process are identified - human resource practices, management style, organizational strategic vision, organizational culture, external partnerships. The research outlines the challenges that companies experience when they change their business model towards implementing a new to the company management system – Lean concept. For better understanding of the term the paper suggests definitions from the authors acknowledged in the field. Part of the research considers some critical points that impede the implementation of Lean. The conclusions are drawn upon considering lean as a complete business system, which change the way organization thinks in striving for a competitive advantage. Keywords: lean implementation, lean enterprise, Lean, challenges, process improvement 3 Table of Contents: Introduction...
Words: 19306 - Pages: 78
...business organization encompasses. Chapter 2 discusses operations management in a broader context, and presents the issues of competition, strategy, and productivity. After you have read Chapter 2, you will understand the importance of the operations function relative to the goals of a business organization. This chapter also describes time-based strategies, which many organizations are now adopting as they seek to become more competitive and to better serve their customers. Introduction to operations management includes two chapters: 1 2 Introduction to Operations Management, Chapter 1 Competitiveness, Strategy, and Productivity, Chapter 2 CHAPTER 1 Introduction to Operations Management CHAPTER OUTLINE Introduction, 4 Production of Goods versus Delivery of Services, 7 LEARNING OBJECTIVES After completing this chapter, you should be able to: 1 Define the term operations management. 2 Identify the three major functional areas of organizations and describe how they interrelate. 3 Compare and contrast service and manufacturing operations. 4 Describe the operations function and the nature of the operations manager's job. 5 Identify the two major aspects of process management. 6 Describe the key aspects of operations management decision making. 7 Briefly describe the historical evolution of operations management. 8...
Words: 18766 - Pages: 76
...examining the reasons why human resource development has become a critical part of an organization’s competitive capabilities, and explaining why people are important in organizations. We will also discuss how human resource development has changed over time, and why it is important in the modern competitive arena. The next section explores how human resource management has been modified to reflect the step changes in markets and production requirements over time. We will describe the nature of the changes to major business eras, leading to an appreciation of how skills requirements have reflected these major changes. After explaining what is meant by strategy, the third section develops key strategic issues in human resource development. We will also investigate how human resources can play a profoundly important part in developing and implementing strategy within an organization. Next, the emergence of human resources as a strategic issue is explored in greater depth. This section explains the critical differences between many Western firms’ and Japanese approaches to human resource development. We will show that human resource development needs to be in place alongside other important human resource issues, including industrial relations, and describe how human resources can become part of the core competence of an organization. Mann-01.qxd 14~8~04 16:05 Page 2 2 Human Resource Development The final section looks at how some firms have developed a set of best...
Words: 12688 - Pages: 51
...Management Evaluation | | Candice Brooks | | | A. Supply Chain Strategy Supply chain Strategies: Vertical integration | * Developing the ability to produce goods or services previously purchased * Buying a supplier or distributor | Few suppliers | Long term relationship with few dedicated suppliers | Many Suppliers | A supplier responds to the demands and specifications of “request for quotation”, with order going to the lowest bidder | Joint Ventures | Formal collaboration | Keiretsu Network | A Japanese term that describes suppliers who become part of a company coalition | It is recommended that KG tools select the Keiretsu network as the company’s supply chain strategy. The strategy is recommended because of its versatility. The tool company need to be able to respond quickly to the need of their customers. Keiretsu is a hybrid of purchasing from a few suppliers approach and vertical integration. The Japanese Word Keiretsu describes suppliers that become part of the company’s coalition. There are two different types of Keiretsu. Horizontal keiretsu are usually organized around a bank and consist of a variety of companies that perform different functions. Vertical keiretsu, are composed of a major industrial corporation and its suppliers in a particular industry. These vertical keiretsu are "held together by fairly predictable transaction patterns and based on implicit long-term contracts, financing and equity ownership. In a vertical...
Words: 4559 - Pages: 19
...directly or indirectly. Hailed as the ‘industry of industries’ by the Management Specialist, Peter Drucker, the automobile industry (US) set standards in manufacturing activity by contributing mass production techniques during early 1910s. The Japanese soon followed by offering lean production techniques in the 1970s. Riding high on economical revival in many developing countries in Asia and Europe, the industry’s global output touched 79,9 million vehicles in 2011. But with a downward slide in market share, the Big Three, Ford Motor Company (Ford), General Motors Corporation (GM) and DaimlerChrysler (DC), was fast losing their dominant position to Toyota, Honda, and Nissan, thereby setting the ground for the emergence of New Six. The report on “Automotive Industry Analysis” consists on a comparison between the Big Three and New Six. Ford, General Motors and Toyota are taken as examples. I. Industry Overview Hailed as ‘the industry of industries’ by Peter Drucker, the founding father of the study of management, in 1946, the automobile industry had evolved continuously with changing times from craft production in 1890s to mass production in 1910s to lean production techniques in the 1970s. The prominent role played by the US till late 1990s had of late been cornered by the Japanese automakers. The global output from the automobile industry touched 79,9 million vehicles in 2011, thereby retaining its leadership in manufacturing activity, providing employment to one in...
Words: 4136 - Pages: 17
...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...
Words: 4718 - Pages: 19
...may suggest that Nike be resolved of some responsibility if the factories also produce products for other companies. 2. What labor standards regarding safety, working conditions, overtime, and the like, should Nike hold foreign factories to: those prevailing in that country or those prevailing in the United States? Answer: The question of whether of whether to hold foreign factories to the same standards as domestic factories is difficult. Some students might argue that Nike should require all factories regardless of their location to maintain the same standards when it comes to working conditions, overtime, and so on. Other students however, may suggest that it would be completely out of line to pay workers the same wages around the world, or require factories to follow expensive safety procedures. Students taking this perspective might argue that doing so could push some factories out of business and leave workers in an even less desirable state. Some students might also argue that if working conditions, wages, and so forth are standardized...
Words: 13231 - Pages: 53
...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...
Words: 8778 - Pages: 36
...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...............................................................................
Words: 8778 - Pages: 36