Toyota production system: an integrated approach to just-in-time
Gespeichert in:
| 1. Verfasser: | |
|---|---|
| Format: | Buch |
| Sprache: | English Japanese |
| Veröffentlicht: |
Norcross, Ga.
Industrial Engineering and Management Press
1993
|
| Ausgabe: | 2. ed. |
| Schlagworte: | |
| Online-Zugang: | Inhaltsverzeichnis |
| Beschreibung: | XVII, 423 S. Ill., graph. Darst. |
| ISBN: | 0898061296 |
Internformat
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| 650 | 4 | |a Automobile industry and trade |x Production control |z Japan | |
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Datensatz im Suchindex
| _version_ | 1804123238566985728 |
|---|---|
| adam_text | Contents
Toyota Production System Japanese Terms xi
Foreword to the First Edition xiii
Preface xv
Acknowledgments xvii
Part I Total System
1. Total Framework of the Toyota Production System 1
Primary Purpose 1
Kanban System 6
Production Smoothing 8
Shortening Setup Time 9
Process Layout for Shortened Lead Times 10
Standardization of Operations 11
Autonomation 12
Improvement Activities 13
Summary 13
Part II Subsystems
2. Adaptable Kanban System Maintains
Just In Time Production 15
Pulling System for JTT Production 15
What Is a Kanban? 16
Kanban Rules 24
Other Types ofKanbans 29
v
vi
3. Supplier Kanban and the Sequence Schedule
Used by Suppliers 37
Monthly Information and Daily Information 38
Later Replenishment System by Kanban 39
Sequenced Withdrawal System by the Sequence Schedule Table 42
Problems and Countermeasures in Applying the Kanban System to
Subcontractors 46
Guidance by the Fair Trade Commission Based on the Subcontractors Law
and the Anti Monopoly Law 48
Supplier Kanban Circulation in the Paternal Manufacturer 53
Structure of the Supplier Kanban Sorting Office 56
4. Smoothed Production Helps Toyota Adapt to Demand
Changes and Reduce Inventory 63
Smoothing of the Total Production Quantity 63
Smoothing Each Model s Production Quantity 67
Comparison of the Kanban System with MRP 71
5. The Information System Between Toyota, Its Dealers, and
Parts Manufacturers 75
The Order Entry Information System 75
The Information System Between Toyota and Parts Manufacturers 79
Production Planning System in Nissan 84
6. Computer Control System in an Automobile Factory 89
Centralized Control System and Decentralized Control System 89
Structure of a Hierarchical Decentralized Control System 90
New ALC System at Toyota 99
7. How Toyota Shortened Production Lead Time 105
Four Advantages of Shortening Lead Time 705
Components of Production Lead Time in a Narrow Sense 106
Shortening Processing Time through Single Production and Conveyance .. 107
Shortening Waiting Time and Conveyance Time 114
Broad Approach to Reducing Production Lead Time 116 ,
8. Reduction of Setup Time—Concepts and Techniques 121
Setup Concepts 122
vii
9. Practical Procedure for Reducing Setup Time 131
Analyzing Setup Actions 131
Procedure for Setup Improvements 132
Informing Operators of Improvements 139
Organization Structure for Promoting Setup Time Reduction 142
10. Standard Operations Can Attain Balanced Production
with Minimum Labor 145
Determining the Components of Standard Operations 145
Proper Training and Follow Up: The Key to Implementing a Successful
System 158
11. Machine Layout, Multi Function Workers,
and Job Rotation Help Realize Flexible Workshops 159
Shojinka: Meeting Demand through Flexibility 159
Layout Design: The U Turn Layout 161
Attaining Shojinka through Multi Function Workers 766
12. Improvement Activities Help Reduce the Work Force and
Increase Worker Morale 177
Improvements in Manual Operations 177
Reduction of the Work Force 179
Improvements in Machinery 183
Job Improvements and Respect for Humanity 185
The Suggestion System 186
Kanban and Improvement Activities 190
QC Circles 193
13. 5S—Foundation for Improvements 199
Visual Control 202
Practical Rules for Seiton 207
Seiso, Seiketsu, Shitsuke 214
Promotion of 5S System 217
14. Autonomous Defects Control Assures Product Quality ...221
Statistical Quality Control 222
Autonomation 224
Autonomation and the Toyota Production System 227
Robotics 236
Company Wide Quality Control 237
viii 15. Functional Management to Promote Company Wide
Quality Control and Cost Management 239
Quality Assurance 240
Cost Management 240
Organization of the Functional Management System 245
Part III Quantitative Techniques
16. Sequencing Method for the Mixed Model Assembly Line
to Realize Smoothed Production 253
Goals of Controlling the Assembly Line 253
17. New Sequence Scheduling Method for Smoothing 265
Basic Logic of Sequence Scheduling 265
Sequence Scheduling Using Artificial Intelligence 270
Diminishing Differences Between the Product Lead Times 275
18. Determining the Number of Kanban Pertinent to the
Alternative Withdrawal Systems 279
Constant Quantity, Nonconstant Cycle Withdrawal System 280
Constant Cycle, Nonconstant Quantity Withdrawal System 283
Changing the Cycle Time of Standard Operations Routine Instead of the
Number of Kanban 285
The Influence of the Supervisor on the Total Number of Kanban 286
Constant Withdrawal Cycle System for the Supplier Kanban 287
19. Computer System for Kanban System Support 291
Technology Data Base Subsystem 291
Kanban Master Planning Subsystem 293
Actual Performance Collection and Transition Subsystems 300
20. Numerical Analysis for Productivity Improvement 303
Analysis Method for Work Place Improvements 303
Performance Analysis of Facility and Worker 307
Evaluation of Overall Production Performance after Improvement 311
Part IV Implementation
21. Review of Kanban System Principles 313
Functions of a Kanban 313
Controlling Production Ordering Kanbans 318
Control of Tools and Jigs through the Kanban System 322
Sequenced Withdrawal and the Later Replenishment System Withdrawal.. 323
22. Prerequisites to Implementing the
Toyota Production System 327
Introductory Steps to the Toyota Production System 327
Introduction of JIT at Toyo Aluminum—A Case Study 3 30
23. Applying the Toyota Production System Overseas 335
Conditions for Internationalizing the Japanese Production System 335
Advantages of the Japanese Maker Supplier Relationship 337
Reorganization of External Parts Makers in the United States 339
Solution of Geographical Problems Involving External Transactions 340
External Transactions of NUMMI 342
Industrial Relations Innovations 343
Conclusion 348
Appendix 1: JIT Delivery System Can Ease Traffic Congestion
and the Labor Shortage 349
JIT Will Contribute to Rationalization of Physical Distribution 349
Genuine JIT System Has Prerequisite Conditions 350
External Environment for Physical Distribution Should Be Rationalized.... 351
Appendix 2: Goals Coordination Method 353
Experiment Outline 353
Conclusion 364
Appendix 3: Quantitative Analysis of Stocks in a JIT
Multistage Production System Using the Constant Order
Cycle Withdrawal Method 367
Introduction 367
Hypothetical Production System 367
Analysis of the Hypothetical System Using the Simulation Approach 376
X
Appendix 4: Quantitative Analysis of Lot Size in a
JIT Production System Using Constant Order Quantity
Withdrawal Method 381
Introduction 381
Hypothetical Production System 381
Modeling the Hypothetical JIT System 382
Epilogue 401
Bibliography and References 407
Index 419
|
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| spelling | Monden, Yasuhiro 1940- Verfasser (DE-588)12069817X aut Shin Toyota shisutemu Toyota production system an integrated approach to just-in-time Yasuhiro Monden 2. ed. Norcross, Ga. Industrial Engineering and Management Press 1993 XVII, 423 S. Ill., graph. Darst. txt rdacontent n rdamedia nc rdacarrier Toyota Jidōsha Kabushiki Kaisha Toyota-Jidōsha-Kōgyō-KK (DE-588)136030-9 gnd rswk-swf Automobiles - Industrie et commerce - Japon - Production - Contrôle Production - Gestion - Japon Toyota (Automobiles) Automobile industry and trade Production control Japan Just-in-time systems Production management Japan Lean Production (DE-588)4287302-2 gnd rswk-swf Fertigungssystem (DE-588)4154150-9 gnd rswk-swf Toyota-Jidōsha-Kōgyō-KK (DE-588)136030-9 b Fertigungssystem (DE-588)4154150-9 s DE-604 Lean Production (DE-588)4287302-2 s 1\p DE-604 HBZ Datenaustausch application/pdf http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=005875495&sequence=000002&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA Inhaltsverzeichnis 1\p cgwrk 20201028 DE-101 https://d-nb.info/provenance/plan#cgwrk |
| spellingShingle | Monden, Yasuhiro 1940- Toyota production system an integrated approach to just-in-time Toyota Jidōsha Kabushiki Kaisha Toyota-Jidōsha-Kōgyō-KK (DE-588)136030-9 gnd Automobiles - Industrie et commerce - Japon - Production - Contrôle Production - Gestion - Japon Toyota (Automobiles) Automobile industry and trade Production control Japan Just-in-time systems Production management Japan Lean Production (DE-588)4287302-2 gnd Fertigungssystem (DE-588)4154150-9 gnd |
| subject_GND | (DE-588)136030-9 (DE-588)4287302-2 (DE-588)4154150-9 |
| title | Toyota production system an integrated approach to just-in-time |
| title_alt | Shin Toyota shisutemu |
| title_auth | Toyota production system an integrated approach to just-in-time |
| title_exact_search | Toyota production system an integrated approach to just-in-time |
| title_full | Toyota production system an integrated approach to just-in-time Yasuhiro Monden |
| title_fullStr | Toyota production system an integrated approach to just-in-time Yasuhiro Monden |
| title_full_unstemmed | Toyota production system an integrated approach to just-in-time Yasuhiro Monden |
| title_short | Toyota production system |
| title_sort | toyota production system an integrated approach to just in time |
| title_sub | an integrated approach to just-in-time |
| topic | Toyota Jidōsha Kabushiki Kaisha Toyota-Jidōsha-Kōgyō-KK (DE-588)136030-9 gnd Automobiles - Industrie et commerce - Japon - Production - Contrôle Production - Gestion - Japon Toyota (Automobiles) Automobile industry and trade Production control Japan Just-in-time systems Production management Japan Lean Production (DE-588)4287302-2 gnd Fertigungssystem (DE-588)4154150-9 gnd |
| topic_facet | Toyota Jidōsha Kabushiki Kaisha Toyota-Jidōsha-Kōgyō-KK Automobiles - Industrie et commerce - Japon - Production - Contrôle Production - Gestion - Japon Toyota (Automobiles) Automobile industry and trade Production control Japan Just-in-time systems Production management Japan Lean Production Fertigungssystem |
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