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Transcript of TOYOTA Production System;KanbanProduction · PDF file ConsultSourcingCorporation TOYOTA...

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    TOYOTA Production System;Kanban Production

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    Pull system production style

    Processing AssemblyMaterial receiving Order

    JIT=The right material at the right time at the right place and in the exact amount.

    Placement of order

    Kanban production

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    Flow of the Kanban production

    Placement of order

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    The concept of production schedule and inventory

    End of month

    piece /day

    the production speed

    the sales speed

    stock-outstock

    Beginning of the month

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    The concept of production schedule and inventory

    End of month

    piece /day

    the sales speed

    stock-outstock

    Max

    Beginning of the month

    Scheduled production amount

    the standard stock

    the safety stock

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    General production style

    Production schedule

    Production schedule ProcessingProcessing AssemblyAssembly ShippingShipping

    OrderOrder  Trend analysis  Analysis of Cycle Movement  Analysis of Seasonal Variation  Analysis of Irregular Component

     Trend analysis  Analysis of Cycle Movement  Analysis of Seasonal Variation  Analysis of Irregular Component

    Demand forecast Demand forecast

    Push system production

    Production schedule

    Production schedule ProcessingProcessing AssemblyAssembly ShippingShipping

    Demand forecast Demand forecast

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    Flow of the push system production

    Processing area (Lathe)

    Assembly area (Welding)

    Material receiving area

    Shipping area

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    Logic of the push system production =Logic from the view of manufacturers

    Large-lot order =Low cost

    Mass production =High efficiency

    Myth of safety stock

    For markets and industries with less fluctuation in which it is easy to predict the demand.

    Purchase of materials Production Inventory

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    Problems in the push production system

    End of month

    piece /day

    Beginning of the month

    Demand forecast (the sales speed)

    stock-outstockScheduled production amount

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    Problems in the push production system

    End of month

    piece /day

    Beginning of the month

    stock-outstockScheduled production amount <

    the actual demand (the sales speed)

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    Problems in the push production system

    End of month

    piece /day

    Beginning of the month

    stock-outstockScheduled production amount >

    the actual demand (the sales speed)

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    Follow the sales speed

    End of month

    piece /day

    Beginning of the month

    Make the production speed follow the actual demand

    Minimum safety stock (the standard stock)

    Pull system production

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