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Totoya Production System: Automation Answer all Change of Demand

Coordination between market research with the production is very important. However market demand must be adjusted to production capacity. The market is very difficult to predict, to the maturity of research to provide valid data on production capacity anticipated to be very important. Automation is one way to answer all that. Automation in addition to providing products with a fast time is also anticipated to jump in demand for goods. JIT is a principle held by Toyota in manufacturing activity. With autonomation system and automation engine then JIT product delivery on schedule and on time will be easily achieved.

Toyota Production System: Reduction of Costs Through Labor Reduction

Sensors that detect the product being run will greatly assist the work of man. For example, sensors connected to monitors and monitors are equipped with automatic recording of data stored in computer memory. All runs automatically. Therefore, the presences of such a worker automation system only check the data and analyze the data provided by the machine. That way the work should be done by several workers can be replaced with 1 worker only, and even then performed at the end of the lot. Thus when it is running the engine A and the machine is running automatically, then the worker is able to run the machine B. Automatic termination of a defective product will occur occasionally in the work cycle. If there is defective then the task of workers just check the type of defective and to take action and run it again. The machine will run automatically again.

Toyota Production System: Automation and Autonomation A Technique to Detect and Improve Defect Production

What is Jidoka? In the world of manufacturing, we are often familiar with the term Jidoka, let alone a company that reference the Japanese manufacturing system. In this case, Toyota is the pioneer of the implementation of an integrated system with the aim of increasing profits and reducing waste. The system is known as the Toyota Production System. Jidoka could mean changing the automation of manual systems into automated system. Just simply press the “start” automatic machine can produce by itself. Jidoka also could mean that control is automatically disabled. To distinguish the two meanings jidoka Toyota calls the second meaning is Jidoka Ninben-No-aru “or literal translation, automation with human reason Both automation and autonomation is a technique to detect and repair defective production of defects and always include a mechanism to detect defective and the mechanism to stop the line or in case of defective machines.

Just-In-Time and "Jidoka"

A continuous production flow or adjustment to changing demand in terms of number and variety, created by achieving two main concepts: Just In Time and Jidoka. Two of these concepts is the main pillar of Toyota production system. Just-In-Time (JIT) basically intends to produce the necessary units in necessary quantities and time required. Jidoka In Japanese terms, can be interpreted as control a defect in the autonomic system. Jidoka support by not allowing defective units from the previous process flow to the next process and messed it up.

Manufacturing Systems Just-In Time

JIT was initially an internal system used by the founder of Toyota Motor Corporation, which is now recommended for all manufacturing industries worldwide and has experienced in terms of its application. The changes produced by forcing issues that occurred have now been integrated JIT system with integrated manufacturing technology and strategic information systems. The addition of support system is a challenge that requires the use era of progress by reason of more reliable and faster. That will not diminish the essence of Just-In Time itself is producing the goods needed in the quantities needed and the time required as well. The system as an internal drive for production and operations management.

Toyota lean manufacturing production system

Toyota uses a production system known as the Toyota Production System or in English called the Toyota Production System, abbreviated as TPS. The production system developed by Taiichi Ohno and Eiji Toyodadari Toyota Motor Corporation aims to provide the best quality, lowest cost and shortest lead time (lead time) through the elimination of waste or waste that occurs at the time of production. Today many manufacturing companies are studying and implementing Toyota’s production system in running the production and operations of the company. Lean Manufacturing concept is basically part of Toyota Production System. The main objective of TPS is to reduce the cost of eliminating the youth (waste) completely to achieve that step taken 1.Make parts that fit with customer orders (JIT) 2.Make parts with cheap price 3.Make high quality parts 4.Make a flexible work system The Toyota Production System basically consists of two main points: “Just In Time (JIT)” and “Jidoka” supported by Kaizen, Stan


In Japan quality control (quality control = QC) or quality assurance (QA = quality assurance) is defined as the development, design, fabrication, and servicing of products that will satisfy the needs of consumers at the Lowest possible cost. Quality control starts with an independent examiner and methods of statistical demonstration soon turned to the method of “self-examination on all units” based on autonomous control against defects in fabrication process itself. Now in Japan, the number of surveillance is less than five percent of the employees of the factory and almost ten percent of all employees of the factory was the supervisor. In Japan, oversight by a special watchdog has been reduced to as little as possible for Several reasons: Trustees Whose activities are outside the fabrication process of conducting operations without value added. In addition, feedback from supervisors on the fabrication process usually takes a lot of time so that parts or defective products continue to

Things to Look For in a reduction of Labor.

In improvements reduce the number of workers on the line, Toyota eliminate wasted operations, reallocate operations, and reduce labor. Disappearance operation completely useless will result in the reallocation operation among workers in the workplace and a partial reduction of labor. Steps to consider reducing the number of workers with Define time for each worker and revise standard operating routine to get rid of it (reduction). To generate the operating manual repair or compensate for changes in production levels, there are three seal the document that must be considered : 1. The removal operations were futile. When the waiting time for each job being measured, he must stand without doing anything after completing terakhit operations assigned to it. With this, everyone will be able to see that he had time to spare, and there would be fewer obstacles if he is given one or two jobs anymore. 2. Reallocation operation. Reallocation conducted on workers A to E, then the waiting time for

The Statistical Quality Control ( SQC )

Statistical Quality Control derived from America in the 1930s as the industrial application of control chart designed by Dr. W.A. Shewhart . This chart was introduced in the Japanese industry after World War II , mostly as a result of roving lecture Dr. W.E. Deming in 1950 . Although statistical quality control is still an important technique in Japanese quality control system , this system also has some disadvantages : • In SQC , acceptable quality level ( AQL ) which determine the products that pass but with a minimum acceptable quality , set 0.5 % , or 1.0 % . The rate was not satisfactory from the standpoint of companies that try to achieve very high quality manufacturers , for example : the number of defects by one in a million . For example : the factory Toyota , quality control purposes is reached one hundred percent or units either zero defect numbers . The reason is simple : even Toyota can produce and sell millions of cars , individually , a customer will only buy one . If t


Itself form of a round-U is that the entrance and exit lines are in the same position. Spatial rotation U have some variation of ‘concave shapes and circles. The advantage of using this layout is its flexibility to increase or decrease the number of workers needed if you have to adjust to changes in the reduction of number of employees or the number of production. Timely production pull system can also be achieved in each process, a round shape U allows multiple regions or areas specifically developed for operation workers Spatial Improper Spatial was not right that avoided Toyota divided into three main categories: 1. Spatial birdhouse, spatial form is the simplest requires that the workers assigned on one type of machine. This spatial type is called spatial birdhouse because usually rhombic, rectangular and triangular 2. Spatial remote island, room layout is considered that there is a dual-function workers, and enable product flow continuously and smoothly between the various types o


Car manufacturing plant in Japan to deploy an industrial robot that is massive , with reasons such as : enhanced security , improved product quality and increased productivity at lower costs . At present , wages continue to rise and the cost of the most simple robot. In addition , the robot can be adapted to the increasing diversity of products than human labor because the robot requires fewer changes in the layout of the process when the design changes. As our technologies advance every year and decade, more students have been drawn to pursuing robotics as a career. If you have interest or have skills and wants to improve it further, check out Torcs’ robotics jobs site Robot and the Toyota Production System The impact of robotics at work relationship does not mean escape from the Toyota production system , but a logical development of that system . The main purpose of robotics , namely cost reduction , quality assurance , flexible production , and respect for humanity . Contributio


Quality control is a small group of workers who learn the concepts and techniques of quality control constantly and spontaneously to provide problem-solving in the workplace. In the Toyota plant, the main purpose of quality control activities is to promote a sense of responsibility of each worker / employee. Structure of quality control Quality control in the factory Toyota has a direct relationship with official organizations in the workplace, therefore all employees must participate in a number of quality control quality control there squad leader and subordinates. Supervisor or foreman section chief and each acts as an advisor. Each plant or division has a committee to promote its own quality control. In the Toyota plant, quality control activities supported by the person most responsible for each factory. There are numerous other benefits to a water softener that might appeal to a home or business. Namely, whole house water softeners can improve the longevity of your water-based ki


As defined in the regulations at Toyota’s plant, the Quality Assurance should be a quality product that it promotes satisfaction, reliability, and economy for consumers. These regulations outline describes the activities of each department of quality assurance at all stages from product planning to sales and service. Furthermore, the regulations say when and what should be guaranteed by whom and where.That rule is defined as when the eight steps that can be used in a series of business activities from planning to sales. Such steps, among others: 1. Planning products. 2. The design of the product. 3. Preparation of fabrication. 4. Purchase. 5. The designation for sale. 6. Examination. 7. Sales and service. 8. The quality audit. Terms whom and where a special dapartemen managers and department name. What, consisting of the goods are secured and operations for assurance and operations to guarantee it.

Promotion 5s System

Promotion 5s depend on top management decisions . When implementing continuous improvement processes such as 5s surely there will be members of management had any doubt about the success or failure of the process. They will say , ” How much productivity will be increased ? ” Or ” How many 5s will help increase the profitability for real?”. Before carrying out processes such as 5s , workers’ way of thinking and his attitude to work must be changed first . All member companies must have sufficient understanding of the true meaning and purpose , and they should integrate its understanding through seminars throughout the enterprise or workplace . Installation of several banners with slogans may be useful as well . For example : ” clean workplace created by the power of all the people ” , or ” there is no waste in the workplace clean ” , and others . Because 5s activities require long-term effort , the whole company needs to understand its purpose . Some members of management may assume tha


Steps to request materials at suppliers : 1. When looking at the empty box material out, then must press the button beside the line . 2. Turn on the lights just below the metal plate that shows the raw material. 3. At the same time , the red light will be lit warehouse bessar material . 4. Overseeing andon – material caller to see the metal plates that are on. 5. Bearer brought the box to the line and release Kanban supplier prior to the production line . 6. Kanban supplier was brought to the post to be checked and classified 7. Kanban supplier then sent to the supplier . Empty boxes already loaded on trucks . Metal plates for each type of material , is essentially a kind of decision- Kanban and Toyota did not mention these metals Kanban . Each box contains lines in addition to material suppliers Kanabn raw . Put the metal plate when the light is added to the file in order of sliding metal lamp. Then the carrier material will take the metal plate from the bottom berkaas and bring it

Rule Kanban

Kanban setting in need to achieve the target JIT Kanban , The following rules need to be done : Rule 1. Taking the necessary product of the process earlier in the necessary quantities when needed. Implementation of this rule, the company’s top management must be able to convince all workers and membuata critical decision to change the way the flow of production, transport, and delivery available. The following sub-rules will also accompany the regulation: • Every decision without Kanban should be banned. • Every decision that is greater than the number of Kanban should be banned. • Kanban must always be affixed on the physical product. Making the Kanban method, the method used for the transport of a variety of spare parts at a certain time with the travel system-around cargo–mix. Rule 2. Process strove to produce products in accordance with the amount taken by the next process. Implementation of these regulations to two balancing the timing of production among all processes. Therefore,


When the standard operation has been set by the supervisor, the supervisor should really be able to do surgery and then ordered his workers to carry out. Supervisor surgery should only be taught, but also explains the reason why the standards have to be maintained, which is standard operating objectives, it provides a stimulus for workers to be responsible for the quality of the product.. In order to ensure that workers or employees did understand these standards, made of two sheets of the key entry operation and operating instructions note the note distributed to the employees. Note the key operation , explained about the important things in all the operations in the standard operating routine, while the operating instructions note , describing the details of each operation on each line and also a method for checking the quality of the product. Both sheet records also contain data that is provided by the standard operation sheets. The sheets of the note are also installed at each proc


In Japanese , has a double meaning jidoka automation and autonomasi: 1) Automation is changing the manual process into a process engine . With this automation , the machine operates by itself when the switch has been pressed but do not have a feedback mechanism to detect errors and there is no means to stop the process in case of a malfunction. The automation of this type can cause a large number of defective parts if any damage to the engine , is deemed unsatisfactory. Go through for more about the HS automation. 2) Autonomasi or autonomation is disabled automatically control ( meaning taken from Toyota ) . To distinguish the two meanings it , Toyota jidoka often call this second type as jidoka ” Ninben -No- aru ” or literal translation , automation with human reason. Although autonomation often involve some type of automation , this will not limit the engine process . Autonomation can also be used in the operation manual. This is different from det


To decrease the time of preparation, first of all need to recognize the state of preparation work that is currently in the factory. Problems that can be encountered when working long setup / setup time that is very varied, among others: 1. Completion of preparation incoherently 2. The setup procedure is not done 3. The procedure was not adhered to in part properly. 4. Materials, Tools, and the mall is not prepared prior to commencement of operations setup. 5. Work attach and detach old. 6. The amount of height adjustment measures. 7. Work preparation has not been assessed properly. This problem can be remedied through the investigation every day and repeatedly check the state of preparation in the actual workplace. Examples of Daihatsu Industry following describes it (M. Greece 1990, T. Morimatsu 1988, and T. Soukura 1987). First of all, standard operating routine sheet for all processes in the printing section to be inspected. For example, processes and standard operating routine that


If making repair work, respect for humanity can be maintained by observing the following rules: Give workers a valuable job. Workforce reduction is sometimes seen as a way to force the workers to work hard without any humanitarian considerations. But this criticism is based on a misunderstanding of the nature of repair work or in case of using the wrong procedure. Interest improvement program is to increase the amount of net operating added with use values that can be done with the same amount of labor. Interest improvement work program is to eliminate unnecessary work like that and using that time to perform a clean operation with added value, so that the overall standard of operation time and the number of workers is reduced / less. If it is difficult to understand the Toyota production system would be difficult to implement, especially in an environment that the union is strong. In the factory Toyota, respect for humanity is a matter of human energy unification with useful and effec