TYPICAL FACTORY LAYOUT

vs
THE TOYOTA APPROACH
WHAT IS THE TYPICAL FACTORY LAYOUT IN MASS MANUFACTURING APPROACH?
WHAT IS THE APPROACH TO FACTORY LAYOUT IN TOYOTA?

RACHEL TATE @00441881

VALERIE CARDOZ @00442956
5/1/16

LEAN INTEGRATING DESIGN AND PRODUCTION

INTRODUCTION

Various factory process layouts.

Basic layouts for manufacturing facilities:

Static or Fixed position build

Product based Layouts

Process based Layouts

The typical factory layout in mass manufacturing approach.

The approach to factory layout in Toyota.

Comparison between the two factory layouts.

Conclusion

LEAN INTEGRATING DESIGN AND PRODUCTION

TYPICAL FACTORY LAYOUT vs

THE TOYOTA APPROACH

TYPICAL FACTORY LAYOUT vs

THE TOYOTA APPROACH

BASIC LAYOUT TYPES

Parts and resources come

together and are assembled
at one place

This method is used to

create large and complex
products such as airplanes
and ships.

Source: http://www.memrise.com/

STATIC OR FIXED POSITION PRODUCTION

LEAN INTEGRATING DESIGN AND PRODUCTION

TYPICAL FACTORY LAYOUT vs

THE TOYOTA APPROACH

BASIC LAYOUT TYPES

Raw Materials

Components

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Su

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nt
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po

Components

s
ie
bl
em
ss

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Co

Raw Materials

Subassemblies

Purchased
Components &
Subassemblies

Assemblies

s
As

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bl
em

Finished Products

6
Product or
Material Flow

PRODUCT-FOCUSED PRODUCTION
Source: Gaither & Frazier,
1999
LEAN INTEGRATING DESIGN AND PRODUCTION

Production
Operations

TYPICAL FACTORY LAYOUT vs

THE TOYOTA APPROACH

BASIC LAYOUT TYPES

Receiving &
Raw
Materials
Storage
Job X

Job Y

Foundry

Rough
Machine

1
2

Shear &
Punch

Fabrication

Painting

5
4

3
Finish
Machine

Deburr

Packaging
and
Shipping

7
8

7
Assembly
Product or
Material Flow

PROCESS - FOCUSED PRODUCTION

Source: Gaither & Frazier,
1999
LEAN INTEGRATING DESIGN AND PRODUCTION

Production
Operations

TYPICAL FACTORY LAYOUT

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LEAN INTEGRATING DESIGN AND PRODUCTION

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TYPICAL FACTORY LAYOUT vs

THE TOYOTA APPROACH

Traditionally, factory layouts focus

on process based departments.
Work is done in batches and
organized through departments.

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to
c
/Fa
k
u
o.

(Weber, 2012)
6

TYPICAL FACTORY LAYOUT

TYPICAL FACTORY LAYOUT vs

THE TOYOTA APPROACH

TRADITIONAL FACTORY

Each silo is as efficient as possible

Traditional layouts assume that more quantity is the key output.

Batch-and-queue system. Allows inventory to build up and wait. Theory is

reduced change over and transport cost.

Product is pushed through to the customer

Traditional layouts usually optimize for a static design

Having the biggest facility or the fastest and largest piece of equipment is
considered efficient.

Use of complex and expensive material handling systems installed to

automate the transportation waste.

LEAN INTEGRATING DESIGN AND

PRODUCTION

TYPICAL TOYOTA LAYOUT

TYPICAL FACTORY LAYOUT vs

THE TOYOTA APPROACH

Toyota wanted to match the production output of Ford. On analysis their

constraints demanded a different process that would work in harmony
with;

Smaller Space

Smaller Cash Flow

Greater model variety

Smaller Client base

By genchi genbutsu they found waste and defects running through the
Ford system, they developed one-piece flow.

Lean manufacturing is about making more and more, with less and less

LEAN INTEGRATING DESIGN AND PRODUCTION

TYPICAL FACTORY LAYOUT vs

THE TOYOTA APPROACH

TYPICAL TOYOTA LAYOUT

One-piece-flow focuses
on the most efficient
flow for the product.

The materials like

people do not want to
wait around for
activity, the system
keeps them flowing.

Defects are found

quickly.

Movement is reduced
through intelligent flow
management.

www.assemblymag.com
LEAN INTEGRATING DESIGN AND PRODUCTION

TYPICAL FACTORY LAYOUT vs

THE TOYOTA APPROACH

TYPICAL TOYOTA LAYOUT

Workstations are flexible,

they can be altered to

change their role/output
and moved to create a
different sequence.

Stations are flexible to

changing workloads.
More or less stations
can be created in the
process.

Standardisation of parts
throughout car models
reduces this need.

www.assemblymag.com
LEAN INTEGRATING DESIGN AND PRODUCTION

10

TYPICAL TOYOTA LAYOUT

TYPICAL FACTORY LAYOUT vs

THE TOYOTA APPROACH

LAYOUT AT TOYOTA

Processes are balanced with each other and ultimately to the demand rate or Takt
time.

Lean layouts focus on reducing waste and increasing value in the process

One-piece-flow attempts to have no inventory and reduce hidden defects

Driven by customer demand. Pulled through the system

Standardization is fundamental to flexibility

Workstations are flexible to work with the demands of the product and customer
needs

Employees are motivated to problem solve and inspect throughout the process.
Machines/the process can be stopped to solve the solution

LEAN INTEGRATING DESIGN AND

PRODUCTION

11

TYPICAL TOYOTA LAYOUT

TYPICAL FACTORY LAYOUT vs

THE TOYOTA APPROACH

http://ocmis.blogspot.co.uk/2013/03/achieving-operational-excellence-and.html
LEAN INTEGRATING DESIGN AND PRODUCTION

12

TYPICAL TOYOTA LAYOUT

TYPICAL FACTORY LAYOUT vs

THE TOYOTA APPROACH

www.toyota.co.jp
LEAN INTEGRATING DESIGN AND PRODUCTION

TYPICAL FACTORY LAYOUT vs

THE TOYOTA APPROACH

CONCLUSION
TRADITIONAL FACTORY

LAYOUT AT TOYOTA

Departments are organized by function;

Each department with separate supervisor and

specialized workers.

Factory is organized into cells with various machines in

sequential order.

Fewer workers, supervisors and forklift trucks.

Much less work in process and no finished goods in

inventory.

Forklift trucks are needed to move inventory

between departments.

LEAN INTEGRATING DESIGN AND

PRODUCTION

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TYPICAL FACTORY LAYOUT vs

THE TOYOTA APPROACH

CONCLUSION
TRADITIONAL FACTORY

LAYOUT AT TOYOTA

Typical batch-and-queue system

One Piece Flow

http://www.flowmotioncafe.com/batch-working-or-one-piece-flow/#post-comments

LEAN INTEGRATING DESIGN AND

PRODUCTION

15

CONCLUSION

LEAN INTEGRATING DESIGN AND PRODUCTION

TYPICAL FACTORY LAYOUT vs

THE TOYOTA APPROACH

REFERENCES

TYPICAL FACTORY LAYOUT vs

THE TOYOTA APPROACH

Flow Motion. (2015, 9 July). Which is more productive Batch or One-piece-flow? [weblog]. Retrieved from
http://www.flowmotioncafe.com/batch-working-or-one-piece-flow/

Gaither, N., & Frazier, Gregory. (1999).Production and operations management(8th ed.). Cincinnati, Ohio
: London: South-Western ; International Thomson.

Toyota. (2016). Childrens website. Retrieved 11th April, 2016, from

http://www.toyota.co.jp/en/kids/car/cooperation.html

Weber, A., (2016). Lean Plant Layout. Retrieved 04th April, 2016, from,
http://www.assemblymag.com/articles/89823-lean-plant-layout

Williams, D. (1994).Manufacturing systems : An introduction to the technologies(2nd ed.). London:

Chapman and Hall.

Zheng, E. (2013, 31 March). Management Information Systems. [weblog]. Retrieved from

http://ocmis.blogspot.co.uk/2013/03/achieving-operational-excellence-and.html

LEAN INTEGRATING DESIGN AND PRODUCTION

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TYPICAL FACTORY LAYOUT vs

THE TOYOTA APPROACH

QUESTIONS?

LEAN INTEGRATING DESIGN AND PRODUCTION

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