Compendium admissions 2023-25
Toyota has developed its production system around eliminating three enemies of Lean
Download 4.08 Mb. View original pdf
|
- Navigate this page:
- DOWNTIME . 1. D efects 2. O
- Common manufacturing principles
| Toyota has developed its production system around eliminating three enemies of Lean 1. MUDA (waste) can be defined in eight types, seven defined by Toyota and non-utilized skills. 2. MURI (overburden) can result from Mura and from removing too much Muda (waste) from the process. When operators or machines are utilized for more than 100% to finish their tasks, they are overburdened. 3. MURA (unevenness) can be found in fluctuations in customer demand, process times per product, or variation of cycle times for different operators. The eight-lean manufacturing mudas can be remembered using the acronym DOWNTIME. 1. Defects 2. Overproduction 93 3. Waiting 4. Non-utilized talent 5. Transportation 6. Inventory 7. Motion 8. Extra-processing 94 Common manufacturing principles Different principles can be applied in manufacturing. Some products are manufactured according to forecasts without specific sales orders. While some products production starts only after the reception of a sales order. Push and pull systems influence the triggering of output. There are also other ways of classifying the type of production. Production can be structured according to the following principles • Make to Stock (MTS) • Assemble to Order (ATO) • Make to Order (MTO) • Engineer to Order (ETO) Make to Stock (MTS) Make to Stock (also called Build to Stock) means that order processing is based on demand forecasts. Products are produced in stock. The MTS manufacturing principle has the highest degree of standardization. Compared to MTO, ATO, and ETO, it is the most forecast-driven but is most suitable for selling standardized products in large quantities. Especially for everyday goods, inventory levels can be kept low since they enable highly reliable forecasts. The order is forecast-driven in the areas of development, design, procurement, production, and final assembly. From the distribution area onwards, the process is ultimately order-driven. Assemble to Order (ATO) The manufacturing principle of Assemble to Order is also known as Configure to Order. It is to cater to Individual customer requirements in production. Assemble to Order is suitable if the stock of finished goods is to be kept low and there are several variations of a product at the same time in the areas of development, design, procurement, and production, forecasts determine production. So, production or the final product is customer-specific, i.e., order-driven. Make to Order (MTO): This manufacturing principle is that sales orders trigger production. In this, Stock levels are kept relatively low, which means that the fulfillment of customer requirements is often associated with longer delivery times, i.e., high lead time. The sales order is forecast-driven in the areas of development and design. The areas of procurement, production, final assembly, and distribution are order-driven. Engineer to Order (ETO) In the Engineer to Order manufacturing principle, the development and design process is triggered directly after receipt of a customer order. The development is partly forecast-driven, and partially order-driven. The areas of design, procurement, production, final assembly, and distribution are generally order-driven in Engineer to Order. This manufacturing principle is particularly suitable for customer-specific products. The degree of standardization is lowest due to individual production. |