Every automaker has their own way of making things that proves to be most beneficial for their business. Toyota production system (TPS) too is one such system that implements the best proven intelligent methodologies in making a car and is supported by highly motivated team members of Toyota who are trained by the Lean Six Sigma program.
Toyota Motor Corporation has created the Six Sigma system to bring out the best quality in a low budget packed within the shortest possible lead-time by eliminating the amount of wastage in multiple forms like material, time, inventory and idle equipment. It is common in most of the organizations to generate a wastage of about 70% – 90% of their total resources. But, TPS on the contrary has emphasized in detecting the reasons behind the generation of such big amount of wastage with the help of a set of Six Sigma tools and dedicated systems and is determined to eliminate them.
Below are some of the strategies shared by the Ontario Toyota dealer about the Toyota production system followed under the banner of Six Sigma:
Minimizing setup times:
Every setup process involves a certain amount of wasteful activities, materials and above all time. These are considered as waste because all these procedures cannot add any material value to the tied-up labor or equipment. Toyota has successfully managed to cut short setup times from lengthy months to few hours and in some cases even to minutes by handling clever procedures like using carts, training the employees to create their own setups.
Minimum Production Strategy:
Manufacturing parts in bulk requires huge setup that pump up the total costs including capital, big list of inventories, unlimited leading time and indefinite defect costs. Realizing this issue, Toyota has invented an ideal method of ‘minimum production’ to bring down the setup cost and now they have made it possible to manufacture wider range of parts in lesser quantities.
Involvement of Workers:
Toyota has instructed their employees to form up well-knit and organized teams who would be offered training and taught responsibility so that they can carry out the necessary specialized and skilled tasks like equipment repairs and maintenance of internal factory manufacturing procedures.
Participation from Dealers:
The Ontario Toyota dealership were happy to reveal that Toyota considers its dealers as an integral part of their company and Toyota production system. Thus, Toyota Dealers are familiarized with the ways and means to decrease the setup times, minimize the production defects, squeeze out excessive inventories and prevent machine breakdowns while taking up the charge to render the best possible output.
Today Toyota Production system is in line with Just in Time, World Class Manufacturing, Stockless Production, Demand Flow Technology and every other modern technique that are known to be simply the various parts of the Six Sigma system of Toyota. The system works on a flow after everything is processed well, when TPS could fetch an order of great improvements in their inventory, scheduling, material handling, and finally in customer satisfaction.