Quality Assurance Team
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Nicolas Lee
Mike Turbak
Steven Seehusen
Ryan Justen
Brandon Asplund
Fall 2004, University of Minnesota
The Toyota Production System
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Unique production system
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Allows for continuous quality improvement
Rated best vehicle in all categories for quality by JD Power
GM, Chrysler, and Ford have tried to develop Toyota
like production systems
Scientific method is ingrained in Toyota’s production
process
Teaches the scientific method to all levels of the
organization
The Four Rules
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The four rules guide design, operation, and
improvement for every product
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Rule 1: Scope shall be clearly defined
Rule 2: Every customer-supplier connection must
be direct and unambiguous
Rule 3: The pathway for every product and
service must be simple and direct
Rule 4: All improvements must be made in
accordance with the scientific method
Rule 1
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All work shall be highly specified
Scope is clearly defined
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Case study: seat installation
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Bolts are always tightened in the same order
Time taken to turn each bolt is specified
Torque of each bolt is specific value
Rule 2
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Every customer-supplier connection must be
direct
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Case study: seat installation
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Acquisition of seat bolt covers by installer
Request is given to materials handler
Request specifies part number, quantity of parts,
location of part supplier, and location of the installer
Coordinated materials handling prevents time lost in
production
Rule 3
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The pathway for every product and service
must be simple and direct
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Case study: seat installation
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Seat installer requests more plastic bolts covers
No forks or loops in supply chain
Installer – materials handler – designated supplier
Goods flow from to specific person or machine
Rule 4
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All process changes must be made in
accordance with the scientific method
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Case study: edging tape installers
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Initially not responsible for solving problems
Assigned a leader to train them formulate and test
hypotheses
Using the scientific method they reduced defect rates by
90%
Toyota’s Ideal Production System
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The output of an ideal person or machine is:
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Defect free
Can be delivered one request at a time
Can be supplied on demand in the version
requested
Can be delivered immediately
Can be produced without wasting labor, energy,
or other resources
Summary of Quality Control
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Define: Define the problem/opportunity, process,
and customer requirements
Measure: Define measures, collect, compile, and
display data
Analyze: Scrutinize process details to find
improvement opportunities
Improve: Generate solutions and ideas for
improving the problem
Control: Track and verify the stability of the
improvements and the predictability of the solution
www.kathyschwalbe.com
References
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Spear, Steven and H.Kent Bowen “Decoding the DNA of the Toyota
Production System." Harvard Business Review Sept-Oct 1999. 97-106.
“Best Initial Quality by JD Power." JD Power and Associates. 2004.
http://www.jdpower.com/cc/auto/releases/search.asp?CatID=1
http://www.toyota.com