Toyotas Kaizen Experience

HISTORY

1897
1926
1933
1935(first passenger car prototype developed)
1937(Toyota Motor Corporation established)
1947(launched its first small car)
1950(Toyota motor sales company was formed)
1952-1970
1974-1990S

Hurdles Faced

Acute Labor shortage.(reasons)

Workers were overburdened.(reasons)
Increased stress for the workers(reasons)
Excessive capital spending

Remedies

Employed many temporary workers

Changed production management(JIT)
Changed human resource management
Changed working condition

Practices Adopted

KANBAN
JIDOKA
JIT
SHOJINKA
KAIZEN

Pre-requisites for Kaizen

Discard conventional
fixed ideas
Dont make excuses.Start
by questioning current
practices
Correct it right away,if u
make mistake
Wisdom is brought out
when faced with hardship
Seek the wisdom of ten
people rather than the
knowledge of one

Think of how to do it,not

why it cannot be done
Dont seek perfection.do
it right away even if for
only 50%of target
Dont spend money for
Kaizen use your wisdom
Ask WHYfive times and
seek root causes
Kaizen ideas are infinite

Waste identified
Overproduction ahead of demand
Unnecessary movements of materials and
products
Excessive inventories
Production of defective products
Idle time
Over processing
Unnecessary movement of people

Implementation of Kaizen
Implemented by the supervisory staff and
engineers
Implemented by workers through quality
circles and a suggestion system

Other activities
Encouraging an active role in quality control
Utilizing employee ideas and opinions in
production processes
Encouraging the practice of Kaizen in every
work sphere

THE MODIFICATION
Allowed plants to set their own annual
production efficiency targets
Method of determining production efficiency
was changed
Best standard time
Reduce of long annual working hours
Method of calculating the production
allowance was altered for blue collor workers
and removed for white collor workers

Reconstruction of the assembly line

Construct an assembly line where workers
could work easily and execute their operations
Organizing a human-centeredTPS
Form a Kaizen mind in everyone so that
he/she willingly does Kaizen

TARGETS
The absence of any operations difficult to
execute
Quality and worker security assurance
Efficiency in logistics
Assembling a vehicle in the shortest time
possible with minimum cost
High investment returns