Process Analysis Report Example

The report emphasizes on how Toyota implemented the Toyota Production System (TPS), a major section of the Lean Manufacturing methods into production, to emerge as the leader in automotive manufacturing. The interesting part of this theory is that Toyota perceived this idea, not from any other automotive production process, but from a mere American supermarket!
At the Ford unit, the Toyota delegates observed that automation of work enabled consistent mass production of components with high quality and substantially reduced the use of skilled labor. But the large amount of inventory stack up at all stages was unappealing. Also theintermittent process flow was highly disturbing. To eliminate these drawbacks, Toyota initiated the Just in Time (JIT) inventory system, introduced intelligent work methods, thorough waste elimination, “pull” system, slow down methods, smart automation, quick change dies, 5S, Kanban system, Poka-yoke, process control charts, Genchi Genbutsu etc.
The outcome from the above changes were remarkable. There was a considerate control of overproduction of components. Elimination of rework and scrap production was achieved. Smart automation ensured smooth work flow in both pull-production and uninterrupted production with constant leveling of work at different assembly stages. Lean manufacturing tools helped achieve the right quality the first time and every time.
The significance of the research is to understand how minor changes in any production unit can ease out over burden (muri), ensure smooth production (mura) and eliminate waste (muda). With this Toyota was able to considerably reduce the lead time and production costs, without compromising on the quality.
The Toyota Production System (TPS) is a framework of concepts and methods for enhancing corporate vitality (Anon, 1998). Today the TPS is not only used by Toyota, but most of the production units, large and small have adopted these tried methods for efficient production.

References

Anonymous, (1998). The Toyota Production System: Leaner Manufacturing for a Greener Planet, Toyota Motor Corporation.