Tmmk 1992 Case

MAPUA INSTITUTE OF TECHNOLOGY

School of Graduate Studies In Engineering Management

Production and Operations Management

Toyota Motor Manufacturing, USA, Inc.

Submitted by

Olivia Mae D. Del Rosario Carla Angelica I. Santillan Angelo C. Santos

Submitted to:

Professor Robin Owens

May 21, 2011

Executive Summary

TMM is facing two major problems: inability of KFS to provide quality seat sets on time and deviation of TMM assembly operation from TPS principles. These two problems are working simultaneously, defect on seat sets was found to be a result of the increase of seat variations while TMM approach to these defects in the assembly line has become a reactive instead proactive. The short lead time given to KFS operation to adjust for the needed throughput has sacrificed the quality of seat sets. Likewise, upon evaluation of the processes involved between KFS and TMM operation, inspection only happens before the delivery of seat sets and continued for over 10 working days. This, therefore, resulted to poor quality and lower efficiency of TMM operation. Additionally, there is a sudden increase of seat set defects or andon pulls in the rear seat installation station where new team members are assigned.

The authors propose to help KFS find the root cause of seat set defects in their operation while a number of seat sets needed for TMM operation be acquired from a new but back-up supplier. TMM must still protect the quality of their Camrys while they pursue for absolute TPSprincipled suppliers. Quality Control team members are proposed to be assigned in receiving dock of TMM to control the inflow of seat set defects into assembly line and to other assembly stations to instill quality control and treatment right away. Moreover, a buddy system in the rear seat installation will enable new team members to work according to TPS principles and work tasks assigned to them.

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Problem Statement/Key Issues There are two key issues: inability of...