Toyota motor manufacturing case study seat problem

Other recalls[ edit ] On February 8,Toyota announced a recall of approximately 7, early model year 4-cylinder Camrys due to the possibility of the power steering hose rubbing into the front brake line which may cause a brake fluid leak. On February 12,Toyota recalled approximately 8, model year 4WD Tacoma trucks for potential front drive shaft issues. The recall involves inspecting a drive shaft component which if cracked will be replaced. Most affected vehicles have not been sold.

Toyota faced significant production issues in the wake of the proliferation of these seats. This was a change from the previous number of 8 variations.

This ratio represented the amount of cars that potentially could have been produced by Toyota under ideal circumstances. This change resulted in 45 less cars being produced per shift.

This result was against everything Toyota valued in its lean manufacturing process. This manufacturing problem had significant impact on many processes within the plant.

Toyota motor manufacturing case study seat problem

It translated into more overtime for the workers, more off-line attention for the cars and decreased levels profit and employee morale.

As heretofore mentioned, the main culprits in this production weakness were seat defects. This triggered an alarm that stopped the manufacturing line and called for the group leader to come and assess the situation.

If the problem could be solved the line was re-started. It was during this quality control process that TMM began to deviate from normal production standards. If cars are being taken off-line it poses many possible problems for the timing and delivery of inventory parts to TMM.

For whatever reason, when it came to solving the problems with the seats, TMM decided to deviate from their best practices.

Who can edit:

When a defective seat was encountered, rather than stop production and fixing the problem, it was decided to keep the defective seat in the car throughout the remainder of the manufacturing process.

Since no other manufacturing process depended on the seat, this was deemed acceptable.

Toyota motor manufacturing case study seat problem

The seat was simply left in the car until a later time. If a defect was found during seat installation, the seat was transferred to the Code 1 clinic where employees would try to fix the defect. Statistics from Exhibit 10 show the number of Andon pulls during the first shift for the rear seat increased dramatically from 20 at the beginning of the month to nearly by the end.Search and browse our historical collection to find news, notices of births, marriages and deaths, sports, comics, and much more.


Subscribe now and save, give a gift subscription or get help with an existing subscription. In , Williams (plaintiff) began working for Toyota Motor Manufacturing, Kentucky, Inc.

(Toyota) (defendant) in an automobile-manufacturing plant. Williams worked on an assembly line, performing manual tasks using her arms and hands. Toyota Motor Manufacturing USA, Inc. (TMM) encountered product proliferation problems with defective seats due mainly to the company's deviation from its /5(1).

Toyota Motor Manufacturing Case Study. Toyota Motor Manufacturing Inc. OM ToyotaMotorManufacturing. What would you recommend? Why?

Toyota USA | Official Toyota Website

The options for the seat problem are: 1. Fixing of bolts and hooks in a proper manner – As the members of the teams were trying to fix the bolt in the front seats they tend to shot the bolt at a . In late , Walt Bernstein, the director of production control for Toyota Motor Manufacturing’s Macon, Georgia operation, was notably frustrated with the plant manager for ChassisCo, a Toyota supplier.

Lean A3 Problem Solving