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Ono Chi, on the timely production of TOYOTA

Supermarket mode

So-called timely production, is to produce the necessary quantity of necessary goods at the necessary time to supply the various processes. Sourcing rapid prototyping manufacturing Manufacturer from China

This way of thinking is not only unique to Toyota, any company will carefully design production plans, use this timely production, planned to work, strive not to do no work, as far as possible to eliminate all kinds of waste. To improve production efficiency.

In Showa 20s, Toyota’s production plan was drawn up at the beginning of the month, with components in mid-month, all assembled at the end of the month, and then managed to complete the monthly plan.

Using this mode of production, no matter how hard the operator processes and assembles, 10 people end up with only one machine.

At that time, Ono Nai Jun is studying the supermarket way, he thought, can not apply the supermarket management mode to the actual production of machinery factory?

In supermarkets, people do things like this: customers calculate how much they spend for several days based on the composition of their family members and the capacity of their refrigerators, take the items they need from the shelves and put them in baskets. Then settle the bill at the exit and bring it home.

Ono notes that the system is just getting what you need when necessary, but it can be used to make it. Sourcing rapid prototyping manufacturing Manufacturer from China

For example, let’s take a look at the Japanese way of delivery. Customers ask for sushi restaurant delivery, if there is only one person, the other side is very difficult to agree. As a result, two people will be ordered. Fruit and vegetable shops and hotels will also be reluctant to deliver because of a small amount, so customers will think: it will be used in the future, buy more, the result of buying some unnecessary things at the time, and in the supermarket. Of course, we will never buy any extra items, just take them home at the necessary time.

The word “timely production” was coined by the first generation of president Yoshihiro Toyoda, but it was challenged. And today’s Toyota production model is Nai Ono. Let’s listen to Mr. Ono’s words:

Timely production

“I had just entered the company, heard parts should focus on the timely production, feel quite interesting. But this idea has not been realized. I did a lot of deep thinking, don’t do this timely production method? I was a strange man, but there is a problem love is the reverse thinking. As a result, I have such an idea, as long as at a time, a place, just take the necessary number of something on the line, which is simply the reverse handling system.

No matter what local companies, including TOYOTA, is generally done before a process only after the operation, and then became the middle process warehouse, but also a lot of volume. After the end of manufacturing goods goods to take after the operation. On the contrary, should be made to do this, first on the end item there, when needed to go there to take the number of required.

This is used when handling things in need to take things one step before, when you need to be added to take away the things. In this way, you can cancel the intermediate warehouse, placed just made out of things, if there is no place, then you must stop production.

The factory is more people, machines and equipment will also have a lot of leeway, if idle and not too good, so he started production, so that there is no place for placing articles. So also to produce things in production, as long as the supplement removed stuff on it. So, you can glance. Workers will understand their own to work overtime or still have ample. If there is no material placed in the products produced in any case where those machines have idle. As supervisor or operator or will be aware of relatively more, personnel allocation is relatively easy, the formation of reverse handling this, as the actual operation method of timely production, it is very effective ”

After the process to fetch the required items

A product such as a car is made up of tens of thousands of parts. If we add up the number of parts in all its processes, the number of parts will be very large. Such a huge process requires that every production plan should not be confused at all. Without changing the production plan, we can achieve the expected production goals in a timely manner, which is very difficult to achieve in reality.

There are many reasons that influence the change of production plan, such as the change of market, various factors of production and so on. Then there will be defects in later processes, whether the operator wishes or not, will have to make the production line to stop or change the plan.

If this situation is ignored, each process produces parts or defective parts that have nothing to do with the later process according to its own production plan. Then there will be a backlog of spare parts inventory that is not needed at all. And the amount of management workload derived from changing the production plan is also very large, just doing the instruction and adjustment work continuously. Management is difficult. Even if it can be managed, tidied up, rustproof and counted, the workload is quite complicated, and these problems make the work site useless.

To make matters worse, it is possible to improperly deal with the situation on each production line because it does not distinguish between normal and abnormal states, or the overproduction caused by too many people could have been improved. But such production plans are hampering improvement. This interplay has led to a spate of futile work on the ground, which has contributed to the further deterioration of business operations. Sourcing rapid prototyping manufacturing Manufacturer from China

Therefore, if only the necessary number of parts are provided to each process in the necessary time, similar to the previous futile work can be removed from the site, and the improvement work will be further realized. It is not possible to solve the above problem by instructing the production plan of each process to transfer the goods from the front process to the back process. That is to say, when and how many parts will be required in the post-process. If these conditions are not clear, too many unnecessary parts will be produced. If too many unnecessary parts are made in excess of time, and then supplied to the backward process, the production will inevitably become chaotic. Production efficiency is reduced.

The procedure of sending the product from the former process to the later process is changed from the latter procedure to the necessary time to get the necessary parts in the former process. Thus changing the flow of components, the previous problems are likely to be resolved.

In other words, the final procedure for manufacturing is the general assembly line, from which the production plan is directed to each assembly line and the production required within the necessary time frame. The necessary types of vehicles, these production lines can be obtained from the previous process to assemble the production line required various parts. Thus, the manufacturing process reverse to the previous process. Even the raw material preparation department follows the chain of synchronization, so that timely production conditions are met, so that the management workload is greatly reduced.

At this time to pick up parts or give production instructions before the process, the tool used is the bulletin board. This form of bulletin board, to ensure that production can be smooth, accurate and timely. It greatly reduces the useless work in production operation, thus approaching the ideal state of production management. It builds up the flexibility of production line and becomes an effective gate to prevent the appearance of useless work.

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