Toyota Motor Corporation: From lean production to the new TNGA platform

Toyota is famous for developing lean production a system of manufacturing methods aimed at reducing waste. This system has been hugely successful for Toyota and has enabled the company to become the world’s leading vehicle manufacturer. Following the global financial crisis, the company began a process of adopting a new global architecture that will vastly change the basis of its production.

Scope

Learn about how car manufacturers deal with uncertainty through market knowledge and efficient manufacturing.

Explore Toyota’s position in the global market in relation to its competitors and global production volumes.

In-depth analysis of Toyota’s lean production system, including analysis of each specific method, such as Kaizen and Kanban.

A detailed review of the Toyota New Global Architecture a modular system of automotive manufacturing.

Reasons to buy

How do automotive manufacturing companies deal with uncertain market conditions?

What is lean production and how has it been adopted by Toyota?

What is Toyota’s new approach to manufacturing and how has it been designed to be even more efficient and responsive?

Companies mentioned

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Table of Contents

OVERVIEW

Catalyst

Summary

DEALING WITH UNCERTAINTY

Accurate market knowledge gives competitive advantage

Current state of the market hints at global growth in supply and demand

Rivalry amongst major players is intense

Contemporary forecasting methods increase confidence in uncertainty avoidance

Ultra-efficient manufacturing and the avoidance of prediction

Evolving manufacturing practices target rapid and reliable, flexible production

LEAN PRODUCTION AND THE TOYOTA WAY

Toyota production system radically changed manufacturing

Just-in-Time saves space, time and money in inventory process

Kanban signals ensure accurate component delivery and efficient production

Jidoka acts as over-arching system of machine-driven quality control

Kaizen sharpens continuous improvement throughout manufacture

Disadvantages start to weigh down on much replicated system

Vehicle recalls shed new light on supposedly error-free manufacturing

Currency fluctuations and economic uncertainty danger to sustainable production

TOYOTA NEW GLOBAL ARCHITECTURE

Building a sustainable and flexible system to stay ahead

Flexibility through rigidity - modular systems form the basis of the new TPS

Fundamental advances in TPS crucial to future production

Financial benefits start to shine through

CONCLUSIONS

Grasping at freedom in a corporate culture of rules and order

APPENDIX

Definitions

Sources

Further Reading

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