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The Five Phases of Six Sigma
The new system aimed at right sizing the machines with respect to the actual volume needed and introduced mistake- proofing so that quality is ensured and proper sequencing of work processes are done. This has inspired him to build the successful kanban system. He even practiced the Dr. Edwards Deming method to incorporate quality at each step of the process from design to aftersales services to the consumers.
The Toyota Production system relies on a number of concepts, that are pull system, elimination of waste, Quick Die changes SMED , non- value added work, U-shaped cells and one piece flow. The pull system defines the flow the material in between different processes as determined by the needs of the customers. The company practices the pull system by using a Kanban system, which provides a signal to the customer that the tools are available to be moved to the next process in the sequence.
The Toyota Production System also identifies the waste , termed as Muda , and recognizes that waste is anything that does not add value to the customers. Wastes are of seven types; that are over-production, inventory waste, defects, waiting, motion, over-processing and transportation and handling.
MSc Lean Six Sigma for Operational Excellence
The system aims at identifying and eliminating these wastes so as to foster efficiency and effectiveness in the production system. Another method adopted by the company is the Quick die changes Single Minute Exchange of Dies which aims at improving the flow Mura of production. The concept is based on the premise that the tools and changeovers should take less than one minute single digit at the maximum. During s and s, the company suffered from the presence of bottlenecks at the car body molding presses.
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The root cause was identified to be the high changeover times that increased the lot size of the production process and drives up the production cost. Toyota implemented the SMED by placing the precision measurement devices for the transfer of heavy weight dies on large transfer stamping machines used to produce the body of the vehicles. Further, the long production lines at Toyota were wrapped using U-shaped cells layout that facilitates lean manufacturing.
A Brief Introduction To Lean, Six Sigma And Lean Six Sigma
This increases the efficiency of the workers to operate at multiple machines at a time. The Toyota Production System TPS practices the one — piece flow whereby the need of the subsequent process is determined by the previous operation.
In other words, one piece is produced at a time opposed to the mass production. Toyota places a single piece between different workstations with the advantage of least variance in cycle time and minimum waiting time. This would help to facilitate optimum balance between different operations and mitigate over- production- which is considered one of the major wastes.
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