Toyota Motor Manufacturing, U.S.A., Inc.
1. What are the problems facing Doug Friesen?
Overview of Toyota Production System
2. How does the TPS facilitate problem identification and problem solving?
3. How is jidoka implemented at Toyota Motor Manufacturing, U.S.A., Inc. ("TMM")?
4. Why are team members encouraged to pull the andon when they discover abnormalities?
5. What are two of the benefits of heijunka, or mixed-model assembly?
6. How is Just-In-Time implemented at TMM?
7. How is the kanban system implemented at TMM?
Seat Problem
8. What is the seat problem?
9. Where, if at all, does the current routine for handling defective seats deviate from the principles of the TPS?
10. Why (with respect to the seat problem) has Toyota deviated from its procedure of investigating problems on the line and stopping the line until the problems are resolved?
Improving the Process in the Overflow Parking Area
11. What are the problems in the overflow parking area (relating to the defective seat problem)?
12. How might the processes in the overflow parking area be changed to reduce the number of cars waiting for correct seats?
Improving the Seat Installation Process on the Assembly Line
13. What are the possible causes of the seat problem on the assembly line?
14. How might the seat installation process on the assembly line be altered to either eliminate the seat defects or to mitigate the impacts of defective seats?
15. Is KFS the cause of the seat defect problem? Recommendations
16. What is the real problem facing Doug Friesen?
17. As Doug Friesen, what would you do to address the seat problem? Where would you focus your attention and solution efforts?