Lean Production System Case Study

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This chapter is discuss and compile information that is related to this final year project which is about the lean production system practice at automotive industry by using one of the lean tool which is standardized work kaizen to improve productivity and reduce production time. In this chapter will briefly discuss about the history and introduction about the Lean Production System. There are 7 type of deadly waste that listed by TPS and with the elaboration of Muda, Mura, Muri. The TPS House Diagram illustrates the manufacturing system and the Malaysia Japan Automotive Industries Cooperation (MAJAICO) program created to improving the Malaysia Automotive Industries. The element in the standardized work is takt time, cycle time,…show more content…
The system is known as Just-In-Time within the Toyoda Group. Just-In-Time is a system where a customer initiates demand, and the demand is then transmitted backward from the final assembly all the way to raw material, thus “pulling” all requirements just when they are required. (Abdulmalek, 2007). A nephew of Sakichi Toyoda, Eiji Toyoda joined their family business, Toyoda Automatic Loom Works and was named as Managing Director. When he was assigned as managing director, Eiji traveled to the United States to study the American automotive industry and also was looking for ways to help his troubled family controlled auto company survive in the postwar world. He had the thought that is might have the possibility to improve the production system at his…show more content…
The house visual metaphor was used to illustrate structural nature of the system. Logically, the strong house is build based on the entire element such as the foundation, the pillar and the roof are also strong. The roof of the diagram is shows the overall goal of TPS included highest quality, lowest cost, and shortest lead time. The first main pillar is jidoka which is automation with human touch. This is done by designing the operation as worker is freely to perform value added work without tied with the machine. The second main pillar is Just-In-Time that is to make sure the right part is in the right quantity at the right time. The purpose of Just-In-Time to reducing the inventories by demand driven (pull) planning of the takt time in order to have a continuous flow of products. The foundation of TPS House consists of Heijunka, Standardize Work and Kaizen. Lastly, to support the whole element needs stability. The metaphor of “house” is intended to show that the elements are part of a larger whole.(Alpenberg,
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