Toyota

Question 1

Key points

Answer 1

• Toyota’s paradox: Reducing cost (waste), will reduce lead time while increasing quality and customer satisfaction.
• Toyoda developed Just in time, no excess inventory and establish partnerships
• Studies of Toyota lead to the framework lean production

Question 2

Toyota Production System - Key points

Answer 2

• Best quality, Lowest cost, and Shortest Lead Time through elimination of waste
• Mix of Jidoka and Just in Time
• Maintained and improved through standardized work and kaizen, PDCA, or the scientific method

Question 3

What are the parts of House of Toyota?

Answer 3

Goal: Highest Quality, Lowest Cost, Shortest Lead Time

Jidoka:
Continuous flow
Takt time
Pull system

JIT:
Stop and notify abnormalities
Separate man´s and machine´s work

Heijunka, Standardization, Kaizen

Question 4

What are the 7 types of waste?

Answer 4

• Defects
• Over production
• Transports
• Waiting time
• Inventory
• Motion
• Processing (överarbete)

Question 5

How can you minimize cost?

Answer 5

Jidoka- Stop directly when detecting problems.

Poka-Yoke - ensure that you cannot do it wrong

Reduce setup cost by reduce setup time use e.g SMED

Question 6

What is 5S?

Answer 6

Workplace organization

• Sort: Make work easier by eliminating obstacles
• Straighten: create a location for everything
• Sweep: keep it clean
• Standardize
• Self discipline: implement it, maintain it

Question 7

What are the 5 steps in Lean Production/Toyota Production System Implementation?

Answer 7

1. Specify value
2. Value stream mapping
3. Create continuous flow
4. Create pull production
5. Perfection