CAN THE TOYOTA WAY OVERCOME THE RECENT TOYOTA SETBACK? — A STUDY BASED ON THE THEORY OF CONSTRAINTS

2010 ◽  
Vol 09 (02) ◽  
pp. 145-156 ◽  
Author(s):  
SIMON WU ◽  
MAURICIO F. BLOS ◽  
HUI MING WEE ◽  
YI-LI CHEN
Keyword(s):  
Lean Manufacturing ◽  
Hybrid Vehicles ◽  
Theory Of Constraints ◽  
General Motors ◽  
Business World ◽  
Manufacturing Techniques ◽  
Problem Solving Strategy ◽  
Solving Strategy ◽  
Industrial Strength

The Japanese carmaker Toyota has long been regarded as the pinnacle of Japanese innovation, manufacturing quality and industrial strength — particularly since it overtook General Motors in 2008 to become the world's biggest carmaker. Its "lean" manufacturing techniques and culture of continuous improvement were the envy of the business world. Companies sent delegations to tour Toyota's factories in the hope that some of its magic would rub off on them. But within a few weeks all this has changed. Problems with "unintended acceleration" of its cars which the firm has belatedly taken seriously, has resulted in a crisis within the company. Toyota's woes were compounded on 9 February 2009 when it said it would also recall 440,000 hybrid vehicles, including the celebrated Prius, to fix a problem with their brakes. The firm's reputation for quality, on which the business was built, is shattered. Its market capitalization has dropped by an amount roughly equal to the entire value of Ford. But the greatest damage has been done by its misreading and mishandling of the crisis. Surrounding this current problem, we came with an interesting question: Can the Toyota Way bring back Toyota to the lead? The aim of this paper has the intention to answer two significant questions. The first question is "Is the Toyota Way safe enough to prevent problems brewing outside its factories?" In order to address this question and get reasonable answer, this study tries to use the Theory of Constraints (TOC) to discover the root causes and countermeasures of how Toyota's Way can bring back Toyota to the lead. The second question is "Can TOC deal with this kind of complicated problem effectively?" From the case study, we successfully answered the two preceding questions, presenting some findings about TOC problem solving strategy.

scholarly journals Industrial Case Study on Lean Manufacturing Implemented on Manufacturing Polypropylene Ropes Industry Amravati

2021 ◽  
Vol 9 (12) ◽  
pp. 1318-1323
Author(s):  
Vipul Deshpande
Keyword(s):  
Lean Manufacturing ◽  
Manufacturing Industry ◽  
Service Industry ◽  
Developing Economies ◽  
Labour Productivity ◽  
Shop Floor ◽  
Industrial Case Study ◽  
Lean Principles ◽  
Manufacturing Techniques

Abstract: Lean manufacturing has been one of the most standard method in the manufacturing and service industry for elimination of waste. Every manufacturing industry has to put in continuous effort for its survival in the current impulsive and competitive economy. The purpose of this paper is to investigate the adoption of lean manufacturing tools and techniques in the manufacturing industries. This paper is based on actual implementation of lean manufacturing techniques. It focuses on the execution of flow from the start until the end of the implementation, types of analysis and tools applied, evaluation methods and how the industry benefited from the implementation. In this case study we particularly focused on Shop floor management, Quality Management (QM), Supplier and Customer Management (SCM) and Workforce Management (WM). After going through various testing on implementation of Lean Manufacturing principles in Micro Small medium Enterprise (MSME), researcher studied thoughts of some author where they discussed pragmatic problems they overcome while implementing lean principles in developing economies MSME. At the end, the result shows that there is monthly increment in capital productivity and labour productivity. And decrement in inhouse rejection, breakdown hours and customer complaint from the implementation of lean.

The Effectiveness of Value Stream Mapping (VSM) as an Improvement Tool for the Manufacturing Operation

2014 ◽  
Vol 575 ◽  
pp. 905-909 ◽  
Author(s):  
Mohd Norzaimi Che Ani ◽  
Mohd Adib Razali ◽  
Kauthar A. Rhaffor
Keyword(s):  
Lean Manufacturing ◽  
Raw Materials ◽  
Value Added ◽  
Handling Time ◽  
Value Stream Mapping ◽  
Value Stream ◽  
Data Problem ◽  
Process Operation ◽  
Manufacturing Techniques

This paper presents the application of the Value Stream Mapping (VSM) as improvements tools at selected case study industry. A VSM process is the transformation of raw materials into finished goods and considered interaction of information, operators, machines and materials. The objectives of this project are to study critical wastes in production line and to recommended new design layout based on Lean Manufacturing techniques. Lean is about performance more with minimized the time, inventory, space, labor, and money. The tool of VSM used in this project successfully achieved its objectives to identify waste and proposing the solution for regarding problems. The lead time was reduced by half, the value added ratio was increased drastically and the cycle time was improved by minimize the handling time. VSM was a magical tool that cans reveals of all the data, problem, process, operation and overall flow of processes to make a certain product.

Across a Spectrum of Inequality

2017 ◽  
Author(s):  
Ryan P. Harrod ◽  
Debra L. Martin ◽  
Misty Fields
Keyword(s):  
Stress Markers ◽  
First Case ◽  
The Social ◽  
Northern Colorado ◽  
Ancestral Puebloan ◽  
History Approach ◽  
Problem Solving Strategy ◽  
Solving Strategy ◽  
The U.S

This chapter involves a comparison of skeletal stress markers, violence, and social inequality in two case studies drawn from hierarchically organized, ancestral Puebloan groups in the U.S. Southwest from the 7th to 13th centuries A.D. (Late Pueblo I through the early Pueblo III periods). The first case study involves the remains of two men from the Room 33 burial chamber at Pueblo Bonito. Employing a contextualized life history approach, Harrod and colleagues first argue that the funerary setting and skeletal remains of these two men independently indicate they were highly ranked elites and ceremonial leaders—not just at the social apex, but were among those organizing hierarchy. The second case study involves the skeletons of women from the La Plata river valley in the northern Colorado Plateau. These women were at the opposite end of the social spectrum, likely slaves captured through intergroup raiding. Their bodies revealed lives marred by abusive, socially sanctioned violence. In death, they were treated with a distinct lack of respect or reverence. The authors link such violence to ritualized activities that functioned as a kind of problem-solving strategy in times of environmental degradation within a marginal ecological setting.

Strategi Penyelesaian Pembiayaan Akad Murabahah yang Bermasalah di BMT UGT Sidogiri Capem Kraksaan

2019 ◽  
Vol 5 (2) ◽  
Author(s):  
Hayatul Millah ◽  
Moh Nurul Amrullah D
Keyword(s):  
Qualitative Research ◽  
Problem Solving ◽  
Case Study Approach ◽  
Study Approach ◽  
Inhibiting Factor ◽  
Problem Solving Strategy ◽  
Solving Strategy

The purpose of this research is to find out the strategies used by BMT in resolving the murabahah financing that is problematic at BMT UGT Sidogiri Capem Kraksaan, knowing the factors that are the supporters in carrying out the problem solving financing strategies at BMT UGT Sidogiri Capem Kraksaan, knowing the factors - factors that become obstacles in carrying out financing strategies that are problematic in BMT UGT Sidogiri Capem Kraksaan. The type of research used in this study is qualitative research with a case study approach. The results of this study indicate that the strategy for resolving murabahah financing that is problematic in BMT UGT is by rescheduling, calling customers, giving warning letters (SP) up to 3 times and discussing the next steps that will be taken by both parties, confiscation of collateral . Factors supporting the murabhaah financing settlement strategy that were troubled by BMT UGT Sidogiri Capem Kraksaan were AOA / AOP officers who always communicated, officers, AOP / AOA always supervised customer financing, always approached customers, routinely collected by AOP officers. The inhibiting factor for the problem solving strategy for murabhaah financing at BMT UGT Sidogiri Capem Kraksaan is the AOA / AOP who are not strict in carrying out their duties so customers are negligent in their responsibilities, AOP officers do not routinely collect from customers, officers do not always report things that are a problem in this murabahah financing to the head of BMT UGT Sidogiri, AOA / AOP officers and Head of Sidogiri BMT UGT are not communicating enough, AOA / AOP is slow in responding to troublesome murabahah financing problems carried out by customers.

scholarly journals MAKING FORMWORK CONSTRUCTION LEAN

2015 ◽  
Vol 21 (4) ◽  
pp. 444-458 ◽  
Author(s):  
Chien-Ho Ko ◽  
Jiun-De Kuo
Keyword(s):  
Lean Manufacturing ◽  
Control Culture ◽  
Site Quality ◽  
New Approach ◽  
Proposed Model ◽  
Key Factor ◽  
Kanban System ◽  
Manufacturing Techniques ◽  
Construction Model

Formwork material and payroll are among the greatest costs in building reinforced concrete structures. Therefore, formwork engineering is a key factor affecting project success. Traditional formwork construction entails non-value-adding activities resulting in waste. The objective of this study is to adapt lean manufacturing techniques to formwork engineering in a bid to reduce waste, specifically by developing a lean formwork construction model. In the model, andon is used to establish an on-site quality control culture, allowing form workers to obtain assistance immediately whenever a problem occurs. In addition, formwork operations are pulled through the kanban system to reduce mould inventory and achieve continuous construction flow. A case study is used to validate the applicability of the proposed model. Results show that the proposed model can effectively reduce waste in the formwork construction flow and increase the value of operations, thus providing a new approach to improving formwork engineering.

scholarly journals Lean Manufacturing and Work Study: Analysis and Integration in an Outbound Logistics Case Study

2019 ◽  
Vol 3 (2) ◽  
pp. 17-25
Author(s):  
Keyword(s):  
Lean Manufacturing ◽  
Work Study ◽  
Study Analysis ◽  
Productivity Improvement ◽  
Critical Areas ◽  
Industrial Sectors ◽  
Study Results ◽  
Manufacturing Techniques ◽  
Study Techniques

Lean manufacturing and work study are both popular and have been widely applied to achieve quality and productivity improvement in several industrial sectors (automotive, health care, and etc.) with high success. Previous studies found that some researchers apply lean manufacturing techniques only, whereas others apply only work study. But not all, some studies have used both techniques for productivity improvement. Therefore, a number of questions remain concerning the gap between the applications of these two techniques. The aim of this research is to fill the gap between these two techniques by reviewing the relationships, differences, and similarities between these two techniques; the results of the two techniques' applications to real case, studies and outbound logistics activities will also be reviewed. A literature review has been conducted to gain an overview of both techniques. Moreover, the case study have shown that both techniques demonstrate enhanced productivity performance. The case study results indicate the relationships, differences, and similarities between the techniques and the benefits of each. In fact, lean manufacturing techniques provide a good overview of processes, whereas the work study techniques focused on critical areas. The effects of applying these techniques are contrasted. Finally, time spent and cost were reduced at the outbound logistics stations.

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