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A Brief History of Car ManufacturingA Brief History of Car Manufacturing
Invention of Automobile in 1880Invention of Automobile in 1880
The Henry Ford Mass Production SystemThe Henry Ford Mass Production System
The Toyota or Lean Production SystemThe Toyota or Lean Production System
Toyota Production System
Toyota Production System
Carl Benze
Gotlib Daimler
Invention of AutomobileInvention of Automobile Carl Benz is generally given credit to Carl Benz is generally given credit to
develop world first automobile in 1985develop world first automobile in 1985
Gotlib Daimler is also contemporary of Gotlib Daimler is also contemporary of Carl Benz who is simultaneously Carl Benz who is simultaneously developed the automobile with him.developed the automobile with him.
Other contemporaries are Wilhelm Other contemporaries are Wilhelm Maybach and Seigfried Marcus known Maybach and Seigfried Marcus known for developing automobile later during for developing automobile later during the same period.the same period.
Toyota Production System
Carl Benze
Gotlib Daimler Replica of the Benz Patent Motorwagen built in 1886
Toyota Production System
Carl Benze
Gotlib Daimler Carl Benze First Motorcyle
Toyota Production System
Carl Benze
Gotlib Daimler
Toyota Production System
Carl Benze
Gotlib Daimler Carl Benze “Vilo” Model of 1894
Henry Ford’s Mass Production SystemHenry Ford’s Mass Production System In 1910 Henry Ford laid the foundation of first highly In 1910 Henry Ford laid the foundation of first highly
organized assembly line system of automobile organized assembly line system of automobile manufacturing.manufacturing.
He organized all the elements of a manufacturing He organized all the elements of a manufacturing system-- people, machines, tooling, and products-- system-- people, machines, tooling, and products-- and arranged them in a continuous system called and arranged them in a continuous system called conveyer system for manufacturing the Model-T conveyer system for manufacturing the Model-T automobile.automobile.
Ford was so incredibly successful he quickly became Ford was so incredibly successful he quickly became one of the world's richest men and put the world on one of the world's richest men and put the world on wheels.wheels.
Ford Motor Company produced “A-Bomber an Hour” Ford Motor Company produced “A-Bomber an Hour” during WWII for USAF using the same concept.during WWII for USAF using the same concept.
Toyota Production System
Ford Motor Company’s Production LinesFord Motor Company’s Production Lines
Toyota Production System
Henry Ford Introduced Conveyer Belt System in Automotive IndustryHenry Ford Introduced Conveyer Belt System in Automotive Industry
Toyota Production System
A bomber an hour: Assembly in Ford Motor CompanyA bomber an hour: Assembly in Ford Motor Company
B-24 bomber final assembly area at Ford Motor Company's Willow Run plantB-24 bomber final assembly area at Ford Motor Company's Willow Run plant
Toyota Production System
Toyoda Family in Auto IndustryToyoda Family in Auto Industry The Allied victory and the massive quantities of material The Allied victory and the massive quantities of material
behind it (“A Bomber an Hour” success) caught the attention behind it (“A Bomber an Hour” success) caught the attention of Japanese industrialists.of Japanese industrialists.
Toyoda family were among those Japanese industrialists who Toyoda family were among those Japanese industrialists who were observing American industrial strength and wanted to were observing American industrial strength and wanted to emulate it by investing in Automotive Industry.emulate it by investing in Automotive Industry.
Toyoda Automatic Loom Company, under the encouragement Toyoda Automatic Loom Company, under the encouragement of the Japanese government, which needed domestic vehicle of the Japanese government, which needed domestic vehicle production partly due to the worldwide money shortage and production partly due to the worldwide money shortage and partly due to the war with Chinapartly due to the war with China
The Toyota Motor Corporation was founded in September The Toyota Motor Corporation was founded in September 1933 when Toyoda Automatic Loom created a new division 1933 when Toyoda Automatic Loom created a new division devoted to the production of automobiles under the direction devoted to the production of automobiles under the direction of the founder's son, Kiichiro Toyoda.of the founder's son, Kiichiro Toyoda.
Toyota Production System
Kiichiro Toyoda
The first production model AA in 1936
Toyota Learns From the Ford Motor CompanyToyota Learns From the Ford Motor Company
Toyota found it difficult to emulate Ford Motor Company whose Toyota found it difficult to emulate Ford Motor Company whose production system was based on Mass Production System.production system was based on Mass Production System.
Post WWII Japanese economy was in shambles and Toyota could Post WWII Japanese economy was in shambles and Toyota could not afford Mass Production of vehicles due to smaller market size.not afford Mass Production of vehicles due to smaller market size.
Toyota’s top bosses begin to design a whole new concept of Toyota’s top bosses begin to design a whole new concept of Production System which is now also known as Just-in-Time Production System which is now also known as Just-in-Time system.system.
Toyota Production System
At Toyota Motor Company, At Toyota Motor Company, Taichii OhnoTaichii Ohno and and Shigeo ShingoShigeo Shingo, are known as the brain , are known as the brain behind transforming Ford production and behind transforming Ford production and other techniques into an approach calledother techniques into an approach called Toyota Production System Toyota Production System or Lean or Lean Production System or Production System or Just-in-Time System.Just-in-Time System.
Taichii Ohno was the Production Boss of Taichii Ohno was the Production Boss of Toyota Motor Corporation and Shigeo Shigo Toyota Motor Corporation and Shigeo Shigo was industrial engineer and consultant of was industrial engineer and consultant of Toyota Motor Corporation.Toyota Motor Corporation.
Toyota Production System
Taichii Ohno
Shigeo Shingo
Ford vs. Toyota model of Production SystemFord vs. Toyota model of Production System
Can be best explained as:Can be best explained as:
Mass Production vs. Lean (JIT) ProductionMass Production vs. Lean (JIT) Production
Toyota Production System
What is Mass Production SystemWhat is Mass Production System
Mass productionMass production is the name given to the is the name given to the method of producing goods in large method of producing goods in large quantities at low cost per unit.quantities at low cost per unit.
This system of production is also known This system of production is also known as Push System or Just-in-Case System.as Push System or Just-in-Case System.
To make it worthwhile, mass production To make it worthwhile, mass production requires mass consumption.requires mass consumption.
With precision equipment, large numbers With precision equipment, large numbers of identical parts could be produced at low of identical parts could be produced at low cost and with a small work force. cost and with a small work force.
Toyota Production System
What is Lean Production System?What is Lean Production System?
Lean Production System is the system Lean Production System is the system designed and evolved in Toyota Motor designed and evolved in Toyota Motor Corporation.Corporation.It is the modified form of Henry Fords Mass It is the modified form of Henry Fords Mass Production System. In some areas its Production System. In some areas its philosophy seem exactly opposite to the philosophy seem exactly opposite to the fundamental principles of Mass Production fundamental principles of Mass Production System.System.This system is generally known as JIT This system is generally known as JIT system, which in fact is an important pillar system, which in fact is an important pillar of Lean Production System.of Lean Production System.The slogan of Lean Production is “Less is The slogan of Lean Production is “Less is best”best”
Toyota Production System
Toyota Production System
Toyota Production System
Just-in-Time• Leveled Production
• Pull System
• Continuous Flow Processing
• Takt Time
• Flexible Work Force
• 3 Ms
• 5 S
Standardized Work Kaizen (Continuous Improvement)
Jidoka (Automation)
• Andon-Fixed Position Stop System• Pokayoke- Fail Proofing
System
Just-in-Time (JIT) SystemJust-in-Time (JIT) System
Just-in-Time means PRODUCING:Just-in-Time means PRODUCING:
a) Only what is neededa) Only what is needed
b) in necessary quantityb) in necessary quantity
c) at necessary c) at necessary timetime
Toyota Production System
Main Components of JITMain Components of JIT Leveled ProductionLeveled Production
Pull SystemPull System
Continuous Flow ProcessingContinuous Flow Processing
Takt TimeTakt Time
Flexible Workforce (Shojinka)Flexible Workforce (Shojinka)
3 Ms3 Ms
5 S5 S
Toyota Production System
Leveled Production means producing Leveled Production means producing various model variations on the same line various model variations on the same line to cater the customer demandto cater the customer demand
Toyota Production System
Conveyer Belt
Leveled Production-Flexible Production LineLeveled Production-Flexible Production Line
Toyota Production System
Pull System (Don’t Push)Pull System (Don’t Push)
Produce only when your customer Produce only when your customer demands the product in the required demands the product in the required quantity.quantity.
Run the production according to this Run the production according to this demanddemand
Toyota Production System
Pull System or Kanban System?Pull System or Kanban System?
Toyota Production System
Continuous Flow ProductionContinuous Flow Production
In TPS it means arranging work inside In TPS it means arranging work inside each process to flow smoothly from one each process to flow smoothly from one step to otherstep to other
Toyota Production System
Toyota Production System
Process A
Process C
Process B
Just-in-Case (JIC) Involves the use of buffer or safety stock
Buffer or
Safety Stock
Buffer or
Safety Stock
Toyota Production System
Process A
Process C
Process B
Toyota Production System
Process A
Process C
Process B
Toyota Production System
Process A
Process C
Process B
Toyota Production System
Process A
Process C
Process B
Toyota Production System
Process A
Process C
Process B
Defect detected at Process B that
actually occurred at Process A
Toyota Production System
Process A Process B Process C
Smooth Flow Processing
Toyota Production System
Process A Process B Process C
Smooth Flow Processing
Defect is detected and countermeasures
are taken immediately
Takt TimeTakt Time: Takt is a German word meaning “meter”. : Takt is a German word meaning “meter”. It is the time to finish a given amount of work-doing a single It is the time to finish a given amount of work-doing a single
operation, making one component, or assembling an entire car.operation, making one component, or assembling an entire car.
Toyota Production System
Takt time =Total daily operating time
Total production requirement
Takt time = 480
100= 4.8 min/ vehicle
Flexible Workforce (Shojinka)Flexible Workforce (Shojinka) Flexible workforce or shojinka means to Flexible workforce or shojinka means to
alter (decrease or increase) the number of alter (decrease or increase) the number of operators within a shop, to equip with operators within a shop, to equip with demand changes.demand changes.
Toyota Production System
Multi-machine HandlingMulti-machine Handling
Toyota Production System
Type of Part
A B C D
Machine (Lathing) 1
Machine (Milling) 2 Machine (Drilling) 3
Machine (Tapping) 4
One person handles one process, four machines
Unfinished Parts
Finished Products
Multi-process HandlingMulti-process Handling
Toyota Production System
Type of Part
A B C D
Machine (Lathing) 1
Machine (Milling) 2 Machine (Drilling) 3
Machine (Tapping) 4
One person handles four processes, four machines
3 3 MM’s’s MMUDA = Non-Value AddedUDA = Non-Value Added
MMURA = OverburdenURA = Overburden
MMURI = Unevenness URI = Unevenness
Toyota Production System
Toyota Production System
1 TON
4 ton
Capacity : 4 tons
Muda . Mura . Muri
12 TONS
Toyota Production System
X
X
2 =
MURI (OVERBURDEN)
6 =
MUDA (NON-VALUE ADDED)
= MURA (UNEVENNESS)
The most efficient way to deliver 12 tons of good to the destination is:The most efficient way to deliver 12 tons of good to the destination is:
Toyota Production System
X 3 =
NO MURI (OVERBURDEN)
NO MUDA (NO WASTAGE)
NO MURA (NO UNEVENNESS)
Toyota Production System
5S1. SEIRI = SIFTING2. SEITON = SORTING3. SEISO = SWEEPING4. SEIKETSU = SPICK ‘N’ SPAN5. SHITSUKE = SUSTAINANCE
SEIRI = SIFTINGSEIRI = SIFTING
Get rid off unwanted stuff from the workplaceGet rid off unwanted stuff from the workplace
Toyota Production System
TRASH
Unwanted
SEIRI = SIFTINGSEIRI = SIFTING
Toyota Production System
SIETON = SORTINGSIETON = SORTING
Arranging wanted items in proper order, which means place for Arranging wanted items in proper order, which means place for every thing and every thing in its place.every thing and every thing in its place.
Toyota Production System
Boxes staked well sorted and orderly manner
Disorderly staking
SIETON = SORTINGSIETON = SORTING
Toyota Production System
SIETON = SORTINGSIETON = SORTING
Toyota Production System
SIESO = SWEEPING AND CLEANINGSIESO = SWEEPING AND CLEANING
Sweeping and cleaning means surface and other areas free from oil Sweeping and cleaning means surface and other areas free from oil and chemicals that may or may not cause slippage, fire or any and chemicals that may or may not cause slippage, fire or any other possible hazard.other possible hazard.
Toyota Production System
SEIKETSU = SPICK ‘N’ SPANSEIKETSU = SPICK ‘N’ SPAN
Toyota Production System
Spick ‘n’ span means visible neatness. A nice, clean and tidy workplaceAffects directly to the performance and quality of workforce.
SEIKETSU = SPICK ‘N’ SPANSEIKETSU = SPICK ‘N’ SPAN
Toyota Production System
SHITSUKE = SUSTAINANCESHITSUKE = SUSTAINANCE Instilling supreme attitude and constantly reminding the Instilling supreme attitude and constantly reminding the
workforce about 5 S philosophy through training, competition, workforce about 5 S philosophy through training, competition, encouragement by the top management.encouragement by the top management.
Toyota Production System
Benefits of JITBenefits of JIT Reduction of direct and direct labor by eliminating non-value added Reduction of direct and direct labor by eliminating non-value added
activitiesactivities Reduction of floor space and warehouse space per unit of outputReduction of floor space and warehouse space per unit of output Reduction of setup time and schedule delays as the factory Reduction of setup time and schedule delays as the factory
becomes a continuous production process.becomes a continuous production process. Reduction is waste, rejects, and rework by detecting errors at the Reduction is waste, rejects, and rework by detecting errors at the
source.source. Reduction of lead time due to small lot sizes, so that downstream Reduction of lead time due to small lot sizes, so that downstream
work centers provide feedback on quality problems.work centers provide feedback on quality problems. Better utilization of machines and facilities.Better utilization of machines and facilities. Better relations with suppliers.Better relations with suppliers. Better integration of and communication between functions such as Better integration of and communication between functions such as
marketing, purchasing, design, and production.marketing, purchasing, design, and production. Quality control built into the process.Quality control built into the process.
Toyota Production System