The Secret of Toyotas Success Toyotas Production system

The Secret of Toyota’s Success Toyota’s Production system 10/16/2021 1

和魂洋才 Wa kon Yo sai (Thiai 魂洋才 Thai Kon Yo sai) l This tradition has been influenced by the idea of "和魂洋才" "Wakon Yousai" advocated by Shozan Sakuma (18111864) since the Meiji Restoration. The idea "Wakon Yosai" means : Japanese spirit combined with Western learning. l An idea of learning Western knowledge, technology, institution and systems without losing Japanese cultural identity. 10/16/2021 2

Toyota’s Production system • In 1949 Toyota produced only 1000 vehicles a month. The industrial productivity of USA was eight times greater than of Japan. l In 2006 Toyota group’s worldwide production plan aims at producing 8. 4 million vehicles. 10/16/2021 3

Toyota’s Production System based on Japanese creativity combined with Western Expertise. l The executives of Toyota knew that Toyota or even the Japanese automobile industry could not survive by simply copying the operations of America. l They knew overproduction can kill their company. l Toyota knew how important it was to manufacture an appropriate number of appropriate (marketable) products at an appropriate time. 10/16/2021 4

Toyota’s Production system is based on Supermarket System Several engines or transmissions for each type of vehicle are placed on shelves and the assembly plant personnel picks up as many engines or transmissions as they need from the shelves. All engines are labeled with information cards which are removed when the engines are picked up. 10/16/2021 5

Working as a Human being supported by the strength of teamwork. Factory workers are working as a human being not as part of the machinery. l Defectives must be cut to zero as much as possible. l If a problem occur the entire line is stopped immediately. Then all workers and supervisors put their heads together to solve the problem. This leads to eliminate every waste of defective, error, or accident and improve productivity. l 10/16/2021 6

Leading Motives of the Toyota Production System Absolutely eliminate waste from every phase of the production process l Waste of stock on hand l Waste of processing l Waste of overproduction l Waste of time on hand l Waste of movement l Waste of making defective products l Excellent service for the customers l 10/16/2021 7

Toyota’s Production system overseas l In 1985 Toyota established a joint venture New United Motor Manufacturing Incorporated (NUMM) with GM in the United States in order to recover a GM factory in California. l In 1990 The Machines that Changed the World published by several professors of MIT introduced Toyota’s Production system to the world. 10/16/2021 8

l The summary of this Power Point Presentation is adapted from the mail magazine, Japan on the Globe (No. 368), October 31, 2004. 10/16/2021 9

The Policy of SONY in UK 10/16/2021 10

The Policy of SONY in UK Representing Japanese Business Management and Manufacturing 2200 British workers and producing half-million TV sets a year 10/16/2021 11

Philosophy of SONY in Europe are independent from SONY in Tokyo but follows overall guidelines. l SONY in UK has got all materials in Europe. l SONY in UK has never been involved in strike for the past 17 years. l SONY highly estimated the Process of Manufacturing and Quality of Engineers. l Top-Management = The voice of Engineers l 10/16/2021 12

The Voice of British Director of SONY in UK 1. High Commitment to the Company l 2. Work Ethic=Team Work and Harmony l 3. A long and mid-term views l 4 A long and mid-term investment in innovated products and people for high quality result l 5. Good communication with shared information l 10/16/2021 13

The Voice of British Engineer of SONY in UK l Constant Involvement of People l Production process and lines are not isolated. l The high quality of Engineers for excellent manufacturing 10/16/2021 14

The Voice of British Line Worker of SONY in UK l Workers are responsible for their work. l Very few mistakes l We could work out some mistakes as a team. l We feel we are part of team with the same target. 10/16/2021 15

Mr. Morita’s Mission, The Chairman of SONY Technology and philosophy are globalized but SONY respects each cultural systems and identities in overseas factories. l Technology enrich peoples life. l Engineers should be involved in top management. l Top Management should have technological backgrounds. l Manufacturing is value adding business. l 10/16/2021 16