1. As Doug Friesen, what would you do to deal with the seat downside? The place would you focus your consideration and resolution efforts? Why? The 2 main causes of seat defects originate with KFS, regarding materials flaws and lacking elements. The seat bolster difficulty is a distant third. As KFS is the accountable occasion the scenario must be addressed at their website. Utilizing the normal TMC first precept of ‘let’s go see it’ after which converge on the 5 Why’s, Doug ought to go to KFS and examine the manufacturing and QC course of.
By specializing in uncovering points on the supply of the seats, it’s possible there might be fewer issues on the TMM plant. The concentrate on QC at KFS may probably remove 113 of the 138 issues reported between 14-30 April, 1992. Within the quick time period, tackle the fast difficulty of the backlog by reconciling orders with KFS to make sure the backlog is cleared. This could require little useful resource and be a fast win. 2. What choices exist? What would you suggest? Why?
Simplifying the seats may scale back the issue since product proliferation seems to added complexity to KFS manufacturing course of, although it’s unlikely that the designers will take this suggestions as welcome given comparable points should not confronted on the Japanese plant. Redesigning the seat or changing simply damaged elements may scale back breakage and set up points, whereas coaching the workers to be extra cautious with set up, or the KFS workers with meeting, may be an possibility.
Changing the provider could be a high-risk possibility that will solely be explored if the problems at KFS have been so irreversible that TMM had no different selection. Whereas all of those choices could probably tackle a part of the difficulty, enhancing the QC course of after which working backwards from there into the meeting and manufacture at KFS will finally have the best single impression on manufacturing effectivity. three. The place, if in any respect, does the present routine for dealing with faulty seats deviate from the ideas of the Toyota Manufacturing System?
One of many main underlying ideas of TPS was constructing in high quality on the road. The reporting of defects on the seat meeting level didn’t look like constant and was solely uncovered by interviewing group leaders on the manufacturing facility flooring. As well as, automobiles have been reported as faulty but continued down the meeting line till completion, the place they have been taken off-line to attend for a substitute seat. Nowhere else on the road have been automobiles eliminated on account of defect: group leaders or manufacturing managers have been accountable for resolving points whereas nonetheless within the meeting line.
The explanations for doing so appeared rational, for the reason that automotive could possibly be completed with a faulty seat, seats wanted to be ordered from KFS and stopping the road for such a prolonged interval would have decreased productiveness. One flaw within the course of was that there have been flaws that could possibly be rectified within the Code 1 clinic. These flaws may have been handled whereas on the meeting line and thus diminished the burden within the clinic, whereas elevating consciousness of frequent defects and their supply earlier within the course of.
The clinic didn’t seem to have the identical reporting tasks because the meeting line since administration weren’t conscious of the principle causes of the defects. four. What’s the actual downside going through Doug Friesen? Course of and suggestions administration issues at TMM and high quality management administration points at KFS have been the underlying causes for the seat issues. Furthermore, the ‘jidoka’ course of had been bypassed within the seat set up course of, exposing a possible weak point within the manufacturing line.
Doug ought to implement an in-line try at fixing seat issues previous to the referral to the Code 1 Clinic. Common suggestions from the clinic in addition to the meeting line would enhance data transparency and establish the supply of defects for administration on the earliest level within the course of. Lastly, the identical processes ought to be adopted at KFS and QC strengthened significantly to keep away from the supply of faulty seats as a lot as attainable. Since this can be a important path to seat supply, no seats ought to go to TMM with out a thorough QC check at KFS.
