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FAL 12031053
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FAL 12031053
OPERATION MANAGEMENT
so, it has overcome great difficulties, brought forth strong leaders, fostered the talents of
many Australians and contributed to the social and economic development of this country.
It has been supported by loyal employees, customers, dealers, suppliers and has
earned the commitment of governments, and many other organisations and individuals in
Australia and throughout the world.The company can have confidence that Toyota Australia
and its people have built the solid foundations necessary to face the challenges of a dynamic
global automotive industry.
FAL 12031053
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TOYOTA PRODUCTION
SYSTEM LAYOUT DIAGRAM
HIGHEST QUALITY, LOWEST
COST, SHORTEST LEAD TIME
JUST IN - TIME
JIDOKA
Continuous Flow
Takt Time
Separate Mans
work and
Machines work
Pull System
STANDARDIZED
WORK
STABILITY
HEIJUNKA
KAIZEN
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To provide the customer with the highest quality vehicles, at lowest possible cost, in a
TPS strives for the absolute elimination of waste, overburden and unevenness in all areas
to allow members to work smoothly and efficiently. The foundations of TPS are built on
standardisation to ensure a safe method of operation and a consistent approach to quality.
Toyota members seek to continually improve their standard processes and procedures in order
to ensure maximum quality, improve efficiency and eliminate waste. This is known as kaizen
and is applied to every sphere of the company's activities.
Just In Time
It is perhaps not widely known that the 'just in time' approach to production that has
now gained almost universal acceptance in world manufacturing was actually pioneered by
Toyota. In fact, a Toyota engineer coined the term itself.
This is a simple but stimulated application of common sense.Essentially, 'just in time'
industrial consists of allowing the entire production process to be regulated by the natural
laws of supply and demand.Customer demand stimulates production of a vehicle. In turn the
production of the vehicle stimulates production and delivery of the necessary parts and so on.
The result is that the right parts and materials are manufactured and provided in the
exact amount needed - and when and where they are needed.Under 'just in time' the ultimate
arbiter is always the customer. This is because activity in the system only occurs in response
to customer orders. Production is 'pulled' by the customer rather than being 'pushed' by the
needs or capabilities of the production system itself.
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The linkage between customer demand and production is made by analysing takt
time, a device for measuring the pace of sales in the market in relation to the capacity of a
manufacturing plant. For example, if a plant operates for 920 minutes per day and daily
demand is for 400 vehicles, then takt time will be 2.3 minutes. If takt times are reduced
more resources are allocated. Toyota never tries to accommodate changes in demand by
making substantial changes in individuals' workloads.
Transmission more members to a line mean that each handles a narrower range of
work. Assigning fewer means that each handles a broader range and the principal importance
of having a well-trained, flexible and multi-skilled workforce.
Within the plant itself, the mechanism whereby production is regulated in this way is
known as the kanban.A kanban is simply a message. For example, in the assembly shop
this message takes the form of a card attached to every component that is removed and
returned when the component is used. The return of the kanban to its source stimulates the
automatic re-ordering of the component in question whereby paperwork is lessened and
efficiency is maximised and also the members themselves are completely in charge.
Jidoka
In Japanese 'jidoka' simply means automation. At Toyota it means 'automation with a
human touch'.In 1902 Sakichi Toyoda invented the world's first automatic loom that would
stop automatically if any of the threads snapped. This principal, jidoka, of designing
equipment and processes to stop and call attention to problems immediately when they sense
a problem is a central concept of TPS.
The most visible manifestation of 'automation with a human touch' at the Altona plant
is the andon cord situated above the line. The presence of the andon cord permits any Team
Member to intervene and bring production to a halt if abnormalities occur.
The Toyota Production System has inherited the principle originated by Henry Ford of
breaking down work into simple steps and distributing those steps amongst employees on the
line. But employees in the Toyota system are in charge of their own jobs. Through their
teams, they run their own worksites. They identify opportunities for making improvements
and take the initiative in implementing those improvements in co-operation with
management.
FAL 12031053
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d. Explain the Job Analysis for a selected job in the operation that you involve.
UTILITIES ENGINEER
The utilities engineer is happened to be responsible in the Energy Management
department whereby the person in charge have to overlook the activities on how the operation
utilises energy and how will the outcome going to look from managing and handling the
energies.
Precisely, the person who hold the position will conservative involve in Special
Projects Implementation, whereby, activities involving electrical fire safety, power plant,
plant rehabilitation and energy efficiency projects.
Besides that, the person has to get themselves involve in Electrical System Management
whereby it is their responsibilities to overlook the overall electrical system in the plant. This
is because it is very important to manage the electricity system as it will cause higher costs to
the company if it is poorly managed.
Moreover, the person in charge also have to encompass in the plant operation under
Energy Retail Competition, which are load forecasting, monitoring and control of
contracted energy, power profile monitoring and power metering system maintenance.
The Toyota managers who share their insights with us on our study missions to Japan tell us
that there are two things that are part of every Toyota' employee's job. They are:
1. Follow the standard
2. Find a better way
This is the essence of kaizen. These simple yet profound rules are what drive every
employee to maintain safety, quality, low cost, and on-time, and strive to make it better. It
sounds so simple, yet how many of us who think we've made good progress on our Lean
journey could say that our organizations live by these rules.
The term "standard" can be misunderstood as something rigid, unchanging, and
absolute. If it is misunderstood in this way, it becomes an obstacle to kaizen.Take the
example of a 1st tier automotive supplier of rubber products. After redesigning the assembly
lines and implementing one-piece flow, it came time to create Standard Work
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The employees who had been actively participating in kaizen resisted documenting
Standard Work. When finally confronted, he explained that he didn't want a published
standard time because he wanted to keep challenging guys to beat their times and get higher
production in fewer hours. What he was talking about was "the record" you had to beat to
have your picture up on the "wall of fame" at the factory. Standard Work is the method used
to achieve that record and must be redrawn each time the record is broken. It is how you train
to beat the new record.
The second part of their concern had to do with the fact that now that they had
freedom to change settings, they did often based on variation in the quality of the cooked
candy and the recipe. The fact that this level of variation exists and requires constant
adjustment is a waste of processing, and demands that standards are set, followed, and
improved.
It was not an easy process, but once we listened to these points and discussed how
setting and improving standards could address their concerns, the kaizen efforts were back on
track.
Another example is during a series of Lean Enterprise overview sessions conducted to
train engineers on how to apply kaizen in their areas. We were warned by the Lean Manager
"Whatever you do, don't mention standards to engineers." We were puzzled, and discovered
that yet again there is a strong belief that standards get in the way of creativity or freedom to
make a better product design or a better process.
Even in engineering "knowledge work", whatever is the most effective current
method is the standard. "Most effective" needs to be based on fact. With engineering work, so
little of it is measured in terms of time or quality that this can be difficult, nonetheless,
standards needs to be documented and shared so that kaizen can happen.