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THE TOYOTA APPROACH
WHAT IS THE TYPICAL FACTORY LAYOUT IN MASS MANUFACTURING APPROACH?
WHAT IS THE APPROACH TO FACTORY LAYOUT IN TOYOTA?
INTRODUCTION
Conclusion
Source: http://www.memrise.com/
Components
ba
Su
s
nt
ne
po
Components
s
ie
bl
em
ss
m
Co
Raw Materials
Subassemblies
Purchased
Components &
Subassemblies
Assemblies
s
As
ie
bl
em
Finished Products
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Product or
Material Flow
PRODUCT-FOCUSED PRODUCTION
Source: Gaither & Frazier,
1999
LEAN INTEGRATING DESIGN AND PRODUCTION
Production
Operations
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
Production
Operations
s: /
tp
t
h
LEAN INTEGRATING DESIGN AND PRODUCTION
/w
ge
.ti
w
w
e
ail
r
t
r
c
rs.
ry
to
c
/Fa
k
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o.
(Weber, 2012)
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TRADITIONAL FACTORY
Having the biggest facility or the fastest and largest piece of equipment is
considered efficient.
Smaller Space
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
One-piece-flow focuses
on the most efficient
flow for the product.
Movement is reduced
through intelligent flow
management.
www.assemblymag.com
LEAN INTEGRATING DESIGN AND PRODUCTION
Standardisation of parts
throughout car models
reduces this need.
www.assemblymag.com
LEAN INTEGRATING DESIGN AND PRODUCTION
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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
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
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http://ocmis.blogspot.co.uk/2013/03/achieving-operational-excellence-and.html
LEAN INTEGRATING DESIGN AND PRODUCTION
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www.toyota.co.jp
LEAN INTEGRATING DESIGN AND PRODUCTION
CONCLUSION
TRADITIONAL FACTORY
LAYOUT AT TOYOTA
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CONCLUSION
TRADITIONAL FACTORY
LAYOUT AT TOYOTA
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CONCLUSION
REFERENCES
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.
Weber, A., (2016). Lean Plant Layout. Retrieved 04th April, 2016, from,
http://www.assemblymag.com/articles/89823-lean-plant-layout
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QUESTIONS?
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