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Toyota Manufacturing

In: Business and Management

Submitted By Someguy32
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Toyota Motor Manufacturing:

At Toyota's Georgetown, KY assembly plant a growing number of 1992 Camrys are sitting off-line with seat problems. The seats are supplied just-in-time by nearby Johnson Control's Automotive Systems (JCI) group. Following the launch of the 1992 Camry, a serious problem emerged at TMM's assembly plant. During the last few days about 45 seat problems have occurred each shift. Every car with a seat defect is supposed to be repaired before shipping it to the sales company, but in some cases it is taking days to effect the needed repairs. With sales approaching plant capacity, the seat problem needs to be solved quickly. This case presents an opportunity to understand the Toyota Production System approach to problem solving.

1. What is causing the "seat problem." A good place to start is defining the “start problem.” Then list the likely causes. Finally, organize those causes in the form of a “cause and effect” diagram (3 pts).

The cause of Toyota Motors Manufacturing seat problem is that they have a sole source supplier for the production of their seats. Kentucky Framed Seat is responsible for the majority of the material issues as well as the missing parts. Kentucky Framed Seat had exceptional delivery performance when they were supplying lesser variations of seats to Toyota. However, their delivery performance and quality would began to take a serious hit that would impact Toyota’s production line. This began when Toyota began to introduce more variations in style and color of the seat for several different Camry models. Toyota originally had 12 different seat styles and that number grew to 36 different seat styles. The sequential pull of 57 second line cycle time left Kentucky Framed Seat with very little time to react. Also, with the Toyota’s practice of Heijunka, there were more line changeovers between runs so the

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