Toyota Motor Manufacturing Case Essay

1350 words - 5 pages

1)As manager of assembly, Doug Friesen should address the problem by focusing on this exception and reasons for allowing such a deviation from Toyota Motors Manufacturing (TMM) normal way of handling problems. He should also look at the communication and synchronization between Kentucky Framed Seat (KFS), the seat supplier, and the plant. One issue that he should look at is why these cars were sitting in the overflow lot for so long. KFS was making special deliveries of new seats twice a day to replace the defective seats, but still there were cars with defective seats sitting in overflow lot for over four days. The other seat issues that Mr. Friesen should look into are the problems caused by cross-threading, breaking of the hook, and the delivery of the wrong seat by KFS. His attention should be focused on finding the root of the problem. He should go down and watch the team who installs the seats into the cars and see if he sees any problems there. He should also consider taking a few minutes out of the day to talk to those employees and see what they think could be done. He should also consider going over to KFS and watching there production lines to see if he can notice any significant problems. Perhaps KFS is being overworked with the new increase in seat variations and finding another supplier or perhaps expanding their own plant to build seats on their own like other companies. Doug should focus his efforts to find the root of the problem and determine if the solution is feasible. Time just needs to be invested to investigate the problem and have the company think together to figure out the problem and solution.2)There are a few different options that I believe Mr. Friesen could follow. The first is to adjust the seat assembly team. He should determine if any changes are needed in the employees, the processes, or the training methods. Another option is to rework the off-line process, there needs to be something done to reduce the number of cars sitting on the overflow lot waiting for new seats. Possibly, a system that notifies employees when a car has been sitting in the overflow lot for more than four hours could be used. This should allow enough time for the correct seat to arrive and the problem fixed. Also, if the employee already knows that the seat needs to be reordered, then a system should be set up for the order to go in right away to avoid waiting. Another possible solution to this would be to have the employee spend a little more time on installing the bolt through the hook so they will be able to use more caution. Doug could also look into a redesign of the seat to solve the problem of the breaking hook. Mr. Friesen did look into this and found that it would cost KFS $50,000 to redesign the seat. The question here would be how long would it take to recover the cost, is it not worth the cost to redesign it, or is there a better way to solve the hook breakage problem. The next option is to look at KFS's production process. Why...

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