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Toyota motor manufacturing usa case study
Short note on toyota production system
Short note on toyota production system
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Lean and the Marine Corps
Lean is a thinking process focused on the entire system. The physical assets and human resources found in a system and how they can be better employed will be discussed and an understanding of the Lean methodology will be gained.
The Marine Corps and the entire Naval Aviation Enterprise cannot afford to run business with the current system. We have struggled for years running the business as usual and we cannot get where we want to be due to many factors. We have insufficient budgets to perform the required activities under the current policies. We have excess inventories and excess "Work In Progress" that is treated as an asset vice a liability. We have no significant surge capacity. Most workers are over worked due to excess non-value added (NVA) work. We cost too much and take too long to complete required work. We tie up excessive fleet inventory due to NVA work processes and the inability to complete work in a required time.
These problems are being examined and processes put in place to prevent the old methodologies from returning due to complacency or stalwartness. The saying," You can't teach an old dog new tricks" is going away. Lean is a total business strategy/methodology to achieve significant continuous improvements in performance through the systematic elimination of all waste resources and time across the entire Naval Aviation Enterprise. Why is it that after decades of doing business "the way we have always done it" is the process under such close scrutiny and propositions of radical change are not being swept under the carpet once again? Through examination and analysis it has been discovered that waste is the culprit. We waste our physical assets and our human resources.
The roots of Lean go as far back as the early 1900's. Henry Ford believed in the continuous flow production and the elimination of waste. Samuel Colt believed in uniformity and the interchangeability of parts. Dr W. Edwards Deming believed that "It is not enough to just do your best or work hard. You must know what to work on." (SkyMark, 2006) The U. S. supermarkets operate with pull systems. Toyota production systems are world renowned for their high quality, efficiency, and low waste. Lean thinking is modeled after the Toyota production system, focused on the total elimination of waste, focused on the standardization of operations and is providing a foundation for rapid continuous improvement in quality, productivity, and customer service.
...states there are three powerful external factors that cloud the Marines’ horizon. The first being the oppressive influence of threat. That threat is rooted in the attitudes or aspirations of the Army, the Navy, or various chief executives. Its nature has varied-threat to the Corps’s repute, to its right to fight, to its very survival. Secondly, the recurrent military affliction called austerity. At worst, they linger in active service and are a hazard to all around them. The third is the dead hand of bureaucracy that lies over the entire military establishment. While the larger services may be able to handle the pressures of bureaucracy, the Marine Corps has neither the instinct nor the time for it. The Marines are an assemblage of warriors, nothing more. Paper massaging and computer competitions do not kill the enemy, which is what the Marines are supposed to do.
Wars have many battles. However, battles do not always lead to war. Marines courageously serve in our nations wars. Their ability to win battles allows our nations to deal with threats quickly without making the situation more dangerous than it already is. Since the year of 1775 the Marines have been the number one branch of the military called upon first. Their ability to execute the most rapid, effective, and efficient military response to disputes anywhere in the world, makes them one of the most respected branches of the military. The Marines Corps are deployed to respond swiftly and aggressively to threats around the world. What distinguishes the Marines Corps from any other branch is the bond formed by their motto “Semper Fidelis.” It was a motto adopted in 1883. “Semper Fidelis” in Latin means “always faithful.” It reminds marines to always be faithful to their mission, to one another, and to the Corps and our beloved nation, no matter the cost. However, we will discuss the history and background of the career, the requirements to obtain the career, the job position and description, and the job reflection and outlook.
When I joined the United States Marine Corps, I knew it would change my life, but I never realized how great those changes would be. I was trained in public affairs as a print and broadcast journalist, and immediately stationed in Okinawa, Japan. Drastic life changes can take a toll both physically and emotionally over time, and it is always important to have a great personal support system to thrive through those times. My senior advisor at the time, Master Gunnery Sgt. (Master Guns) Charles Albrecht, turned out to be one of the best supporters I could ever ask for.
The United States Marine Corps is known as one of the worlds most elite fighting groups. Marines are looked highly upon by most people in American society. However, The Marine corps has had a rough journey since their birth date on November 10th, 1775. While the American people felt and still feel that the Marine Corps are vital in our military. Though the Marine Corps was formed originally for amphibious warfare they have proven themselves powerful “in every clime and place”. Some however feel the United States should integrate the Marine Corps into the United States Army believing that both are performing the same tasks and that having another branch is just causing the defense budget to be stretched out amongst all branches. This is one of the reasons the Marine Corps has been disbanded in the past along with peace time movements were the United States Navy was also disbanded. Even with the Marine Corps’ struggle to remain one of Americas elite fighting forces the people have always rallied behind them to keep them afloat.
There is a lot of literature on the concept of continuous improvement (CI). Studies show that CI is very important to creating competitive advantages in highly competitive industries such as the automobile industry (Bhuiyan & Baghel 2005; Li et al. 2009; Schaeffer, Cadavid, & Backström 2010). These studies suggest that manufacturing firms use CI to eliminate waste in all organisational systems and processes (Bhuiyan & Baghel 2005; Li et al. 2009). Currently, manufacturing firms use lean manufacturing, six sigma, lean six sigma, and the Kaizen methods of CI methodologies to reduce wastages, simplify the production line, and improve quality (Swink & Jacobs 2012).
Simon Sinek’s idea and concepts of leadership are very similar to ones used by the Marine Corps. The Marines are one of the most successful military organizations around the world. They have achieved success by accomplishing missions and winning battles. Battles fought in difficult terrains, climates and circumstances. They have thrived in times when other military branches are better funded and equipped and never lost sight of their purpose and goal. Marines always seem to defy assumptions. They appear to have something special and different when compared to the other military branches. Extract young man and woman from a broad society filled with different cultural backgrounds and make them a Marine. Furthermore, they prepare these young individuals to fight for this country and give their life if necessary defending it. Marines have no problem standing out. The Marine Corps and Simon Sinek’s ideas and concepts for successful leadership are related because both know “why” they do what they do,
The Military defends its country and citizens by any means necessary. The power structure of the military is the most well known aspect to civilians, but there is much more to the armed forces than that. Each tear of the power structure has a responsibility to watch over the lower tears, making sure they are doing their job correctly and build their individual records. Each service member relies on his/her record to dictate how they are treated and advance in the military. In addition to the rank system and individual record, there is a code of conduct in the Military, that is specific to each branch, which must be followed or severe disciplinary action will be taken. The practice of panopticism is most prevalent in the Marines, the strictest
Lean Six Sigma is a methodology that creates processes within an organization to cut waste and improve the company’s performance. However, studies have shown that over the past decade applying Lean Manufacturing and Six Sigma can create problems for companies financially and potential problems for employees. Companies should take great care before implementing a Lean Six Sigma solution because in some instances, going lean can do more harm than good both financially for the organization as well as destroying employee loyalty and moral.
Persoon, T.J., Zaleski, S., & Frerichs, J., (2006) Improving preanalytic processes using the principles of lean production (Toyota Production System). Am J Clin Pathol. 2016 Oct;3(9):278-78. 2006 Jan;125(1):16-25.
Abrashoff begins the book by informing the reader of how his story begins; when he is given command of the USS Benfold. The Benfold was the Navy’s most advanced guided missile destroyer the Navy had in 1997 and its command was to be one of the Navy’s top innovators. Unfortunately, Abrashoff points out some flaws with the Navy’s personnel management that I found to be shocking. First, was that “nearly 35 percent of the people who joined the military annually, wouldn’t complete their enlistment contracts.” (p.2) Such turnover can be understood by many business managers in the service industry, but unlike the quick and cheap training process for them, the cost for the military (taxpayers) is astounding. Abrashoff estimates that it cost roughly “$35,000 to recruit a trainee and tens of thousands more in additional training costs to get new personnel to the basic level of proficiency.” (p.2) Curbing this trend on his own ship and eventually helping to achieve a decrease overall in the mil...
A LEAN Company is our best description and our business philosophy (creating more value for customers with less resources), which pursues to deliver what the customer wants, when they want it, at maximum value with minimum misuse.Through the application of LEAN, we achieve more fulfillment as it helps to reduce the possibility to constantly be fighting a battle against difficulties. Besides, we promote a Continuous Improvement Culture in our performance.
Toyota is a pioneer of the LEAN manufacturing principle. Lean, as a process, is a way to add value to customers while minimizing waste (LEI, 2011). It can also be thought of in terms of flow, which is how Toyota likes to think of it. It is simply a process of decision making where the problems tend to be thought of in terms of flow, reducing starts and stops or unnecessary motion increases flow, reducing waste.
Toyota’s core competencies seem simplistic, yet they are very powerful. There are two in which they focus on which is continuous improvement and respect for people. These core competencies are a part of their production system, better known as the Toyota Production System (TPS). The TPS is based on the philosophy “completely eliminating all waste”. Excess inventory, defective products, and unnecessary processing steps are all inclusive when discussing excessive waste, which eventually negatively effects the corporation as a whole. In 1924, Sakichi Toyoda created the Toyoda Automatic Loom, which improved productivity and work efficiency by eliminating wasteful practices and defective products. Kiichiro Toyoda believed that “the ideal conditions for creating things are more successful when machines, facilities, and people work together to add value without generating any waste.” (The orgin of the toyota production system,
Lean production is an approach to production developed in Japan. Toyota, the Japanese car manufacturer was the company that invented lean production. The whole aim of lean production is to reduce the quantity of resources used up in production. By doing this, lean production uses less of - factory space, materials, stocks, suppliers, labour, capital and time. Lean production reduces costs, increases efficiency and output and improves motivation. Lean production involves using a range of practices designed to reduce waste and improve productivity and quality.
In 1950s, Toyota has developed lean thinking. The Toyota Production System aspires to minimize waste and increase efficiency while at the same time enhances its product quality. From this initiative, Toyota managed to widen its competitive edge by employed fewer employees in the car production with a small number of flaw products.