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Toyota Case Mgt

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Toyota Case

Operation Management

Optional Case #1

Optional case 1 1. What would you do to address the seat problem? Where would you focus your attention and solution efforts? We would focus on a series of actions: • We would first collect data on seats defect issue and try to find out what is the cause of the problem using the 5 Why's analysis. On the other hand we would ask KFS management to do the same thing. Then arrange a meeting with people involved in QM and come up and agree on a solution. 
 TMM should investigate the issue of why are there differences in the 1st shift and 2nd shift at the rear seat installation (left as well as write hand side)?
 KFS should investigate what is wrong with rear seat: hook, lack of communication/synchronization between team KFS and TMM team. • In the effort of addressing the seat problem, we would also build a tiger team with the specific target to solve this issue in a determined period of time. The team should have just this issue to solve (a project based activity). Team members should be managers from TMM (mandatory Shirley Sargent, Da Prille, Lewis, Creemens) and with participation of KFS representative managers and somebody experienced from Tsutsumi. Taking into consideration that Tsutsumi didn't report so far any problem with the same engineering drawings, and also looking at their decrease in defects rate (from 7 occurrences per shift to one per shift by April), it looks that if they had a problem with the seats, they managed to solve it from the beginning. So, they should act like a benchmark for TMM; however, nobody asked them about it, even both plants belong to the same company. So internal cooperation should be encouraged between both factories. • In this team, as framework for thinking, we would encourage the team to use the Six Thinking Hats Method, for getting the real causes and finding optimal

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