Toyota Motoring Manufacturing

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1) How does the andon procedure work and what are its fundamental aspects? How much does it cost to stop the line? What are the benefits of stopping the line?
The andon procedure is adopted by Toyota Motor Manufacturing to ensure quality of their products. It involves the pulling of the andon cord whenever production at a work station is unable to be completed within the cycle time, or whenever any problem is faced. Pulling the andon cord will alert the team leader to the station. If the problem can be corrected immediately, assembly is resumed by pulling the andon cord again. However, if the team leader is unable to solve the problem, the line is stopped. With this process, Toyota is able to manufacture quality products and prevent …show more content…

This led to an increase in inventory in the overflow parking area where the cars waited for KFS’ special delivery.

3) How, if at all, does the current routine for handling defective seats deviate from the principles of the Toyota Production System (TPS)?
The current routine deviates from the TPS principles of Jidoka and Just-in-Time (JIT) production.
JIT Principle
TPS Current Routine (deviation)
Produces only what was needed, how much was needed, and only when it was needed. Any deviation from true production needs was condemned as waste. Defective cars remain in inventory and some have to wait for replacement seats to be delivered. Cars are not produced at maximum capacity. Thus, consumer demand is not met on time.
Jidoka Principle
TPS Current Routine (deviation)
Make any production problems instantly self-evident and stop producing whenever the problem was detected. Insisted on building in quality in the production process and condemned any deviation from value-addition as waste. Does not follow the jidoka principle - instead of stopping production and waiting for the new seat to arrive then fixing the seat before production restarts, Toyota continues with production and only fixes the seats after production ends

4) As Doug Friesen, what would you do to address the seat problem? Where would you focus your attention and solution efforts? What options exist? What would you recommend? Why?
There are several solutions to address the seat problem in the

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