Toyota is the seventh largest company in the world and the second largest manufacturer of automobiles with production facilities in 28 nations around the world (Lexus, 2007). In 1933, the direction of the founder’s son, Kiichiro Toyoda established history of Toyota.
Taichi Ohno, the Vice President of manufacturing for Toyota is generally credited as the father of Toyota Production System (TPS) (Vorne, 2010) TPS is synonymous with Lean Manufacturing and Lean Production. TPS is a manufacturing methodology. The goal of TPS is to maximize value by eliminating waste. TPS is perhaps the most powerful model devised to-date for efficient design and management of large-scale ...view middle of the document...
Besides that return on investment by reducing inventory levels, reducing variability product quality, reducing production and delivery leads times and reducing other costs (Vadim, n.d.). This is because JIT seeks to achieve a “production on call” at all stages and also to produce quality products efficiently through the complete elimination of waste, inconsistencies, and unreasonable requirement on the production line (Usman, 2010; Minoura, n.d.).
JIT manufacturing means producing the items in necessary quantities at the necessary time (Vadim, n.d.). As we know that people involvement, plants and system are the basic elements of JIT. Besides that, JIT in sales and marketing is to good support from customer and agreements, and also to minimize the chance of creating implementation problems (NUS, 2009).
The word of Jidoka is invented by Sakichi Toyoda, Founder of the Toyota Group (Jishuken, n.d.). We know that Jidoka is a manufacturing high-quality product in TPS because it enables to help human resources to operate to build-in quality to each process and separate manpower and machines for more efficient work. Jidoka is known as “autonomation” or “autonomous automation”, meaning automation with human intelligence (Lean Jidoka, n.d.). Jidoka also refers to “automation with a human touch,” this usually illustrated by example of a machine that will detect a problem and stop production autonomatically rather than continue to manpower and produce bad output (Jishuken, n.d.; Lean Directions, 2010).
Jidoka is one of the pillars of the TPS. Jidoka forms the basic of empowerment of the workforce and the machine to practice for stopping the production line when something goes amiss such as equipment malfunction, quality issues or late work (Strategosinc, n.d.; Lean Jidoka, n.d.; TMMK, 2006). Jidoka also helps to avoid the passing of defects, to identify and correct problems areas with using localization and isolation, this is because it to avoid problem will face in sales and marketing. Toyota believes that Jidoka possible o built quality at the production process (TMMK, 2006).
Andon is one of the main of Jidoka (TMMK, 2006). Its origin is in the Japanese words for “lamp” and means “light” (Gemba Research, 2007; Gembutsu, 2009). In Lean Manufacturing, Andons have many different types, such as visual control, visual indicator signaling, visual display and visual management (TMMK, 2006; Gembutsu, 2009; Vorne, 2010; Gemba Research, 2007). Andons are lights placed on machines or on production lines to indicate operation status based on colour, such as green for normal operations, yellow when assistance was needed and red when the line down (Vorne, 2010; Gemba Research, 2007). Besides that, it often combined with an audible signal such as music or alarms (Gemba Research, 2007). Andon system is empowerment and effective communication and help human resources to increase their...