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Toyota Production System
at
TOYOTA KIRLOSKAR MOTOR PRIVATE LIMITED
1 Introduction to Toyota
2 Profile of Toyota Kirloskar motor.
3 Toyota Production System practices in TKM.
4 Overview of TKM Logistics.• Just In Time
• Kaizen- (Continuous Improvement in logistics)
5 Future “Supply Chain” Direction.
CONTENTS:
TOYOTA MOTOR CORPORATION
• Established in 1937 in Japan
• 160 Countries - 5400 Dealers.
• 26 Countries - 46 Plants
• Sales of 15.1 trillion Yen in March 2002
• 247,000 employees worldwide.
• Manufacture of all types of Vehicles including Luxury & Small Cars.
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2000
3000
4000
5000
6000
7000
8000
9000
GM Ford Toyota VW Daimler
Chrysler
P S A Honda Nissan Renault Fiat
Company
No.
of
Uni
ts S
old
(1=1
000
Uni
ts)
Automakers ranking worldwide based on vehicle sales
Toyota is 3rd Largest Auto Maker in the World
2003 First quarter Result Toyota – No. 2
TKM is the 14TKM is the 14thth & almost the last automobile manufacturer & almost the last automobile manufacturer to enter in Indian automobile industryto enter in Indian automobile industry
TOYOTA KIRLOSKAR MOTOR PRIVATE LTD
Establishment : 6th October 1997
Location : Bidadi near Bangalore in Karnataka State
Start of Production : Dec 1999
Production Model : Multi Purpose Vehicle Passenger car
Production Capacity : 50,000 Units/year
Investment : US$ 170 Million (Phase I)
No. of Employees : 2300
PRODUCTION / SALES
0
10000
20000
30000
40000
50000
Vol
ume
Corolla 1383 9000
Qualis 21086 28509 28989 34000
2000 2001 2002 2003
Crossed1Lakh cars in Sept 03
COMPLETE VIEW OF TKM PLANT
In-house facilities at TKMPress Shop Weld Shop Paint Shop
Assembly Shop Inspection Area
ISO 14001 WITHIN THE FIRST YEAR
TPS AT TOYOTA
KIRLOSKAR MOTORS
IMPLEMENTATION OF TPS IN TKMVEHICLE QUALITY TRENDVEHICLE QUALITY TREND
0
LE
VE
L
TIME
MAINTENANCE
IMPROVEMENT
REFORM
TKM
GLOBAL TOYOTA LEVEL
AS
ON
DA
TE
GLOBAL YIELD RATIO COMPARISON
5 8 . 0 0 %
6 0 . 0 0 %
6 2 . 0 0 %
6 4 . 0 0 %
6 6 . 0 0 %
6 8 . 0 0 %
7 0 . 0 0 %
MODELS
IMPROVEMENT IN YEILD AS ON AUG-01 6.00% 3.42%0.56% 0.00% 0.00% 0.50% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 2.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 1.26%0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.85% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 1.48% 0.00% 0.00% 0.00% 0.00%
DATA COLLECTED DURING LINE-OFF OF QUALIS 64.10% 64.10%69.20% 69.70% 68.90% 68.40%68.80% 68.40% 68.20%68.10% 68.00%67.99%67.90% 67.65% 67.27% 67.20% 64.80%66.50% 66.50%66.27% 66.10%66.00%65.80% 65.50%65.40% 65.30% 63.70%64.90% 64.80% 64.80% 64.80%64.70% 64.60% 64.20% 64.20%64.16% 64.10% 64.10% 63.70%63.59% 62.50% 63.10%63.00%62.80% 62.80%62.60% 62.60% 62.57% 62.50%62.50% 60.70%62.00%61.50%60.86%59.70%
133W133W140N 797T 209T 430T 351T 143N 440T 350T 231T 076W 325N 316T 040W 390T 415T404T 395T 065W 210T 186N 465N 450T 153T 391T 970T 081N 652T 651T 630T 702T 525T 828T 191N095N 133W971T 609T 108T 051N 701T 541T 860T 540T 250T 085N 908T 890T 477T 870T 185T 780T 277N 781T
This da ta exc ludes 15 .474 kg /veh o f
mater ia l saved by sending o f fa l s to
suppl ier parts l ike NTTF, STANZEN &
This i s the average
yield ratio of all the
supp l i er s I . e . STTI ,
QUALIS BASIC YEILD RATIO
TPS
Just In Time Heijunka Visual Control Board Built in Quality
Team Work
KaizenJidokaGenchi GenbutsuM-I-R
Standardized Work Challenge
0
500
1000
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3000
3500
Dec-
99
Jan-
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Feb-
00
Mar-
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Apr-
00
May-
00
Jun-
00
Jul-
00
Aug-
00
Sep-
00
Oct-
00
Nov-
00
Dec-
00
Jan-
01
Feb-
01
Mar-
01
Apr-
01
May-
01
Jun-
01
Jul-
01
Aug-
01
Sep-
01
Oct-
01
Nov-
01
Dec-
01
START OF VOLUME PRODUCTION
START OF SECOND SHIFT
START OF TAKT UP (10’ - 8’)
TAKT DOWN(8’ - 9.25)
TAKT UP (9.25’ - 8’)
TAKT DOWN (8’ - 9.25’)
TAKT UP (9.25’ - 8’)
Units/Month
TAKT UP (7.5’ - 7’) &
TAKT DOWN (7’ - 8’)TAKT UP
(12’ - 9.25’)TAKT DOWN
(8’ - 10’)
TAKT DOWN (9.25’ - 12’)
TAKT UP (8’ - 7.5’)
OVERVIEW OF
LOGISTIC OPERATIONS
• Just - in - time supply
• Small lot - high frequency delivery
• Palletised cargo
• Standardized packaging
TKM’S Logistics concept
TKM SUPPLY CHAIN
P
W
T
A
Insp.
DEALER
CBU LOGISTIC
CUSTOMER
Material
Information Information
Parts
TMC &Overseas Plants -
CKD Parts
Parts
Information
OrderInformation
OrderFeed Back
P Press shopW Weld shopT Paint shopA Assembly shopInsp Inspection
Steel Maker
Material Supplier
SteelCenter
PartsSupplier
Delhi Transit Dock (2600 Kms)North Area - 19 Suppliers
Pune Transit Dock (900KMS)West Area - 13 suppliers
Chennai Transit Dock (370 KMS)18 Suppliers
Bangalore PlantSouth Area - 28 Suppliers
SINGAPORE(TRANSHIPMENT)
THAILAND
JAPAN
PHILIPPINES
INDONESIA
TMC
TAIWAN
TAP
TAM
STM
TKM
TKM LOGISTICS OVERVIEW
KUOZUI
LOCAL SUPPLIERS DISTRIBUTION
Delhi Cross Dock
North Area - 19 Suppliers
Pune Cross Dock
West Area - 13 Suppliers
Chennai Cross Dock
18 Suppliers
Bangalore Plant
South Area - 28 Suppliers
Kanban suppliers- 40
(74% parts)
JUST- IN-TIME
JUST IN TIME
MAKING MATERIAL AVAILABLE TO NEXT PROCESS
• WHAT IS NEEDED The right part
• WHEN IT IS NEEDED At the right time
• IN JUST THE AMOUNT NEEDED.
JUST IN TIME
Procurement Methods for local parts
• Scheduled ordering for far of suppliers with cross dock.
• Kanban based ordering for nearby suppliers without cross dock
• Jumbiki ordering
Supported by
In-house Logistics systems
• Welding (Chorukyu system)
• Assembly (Sequential supply system)
Logistic System - Milk run system
T P S
Conventional System
SUPPLIER-A
SUPPLIER-B
SUPPLIER-C
TKM System
TKMSUPPLIER-B
SUPPLIER-A
SUPPLIER-C
LOW FREQUENCY
BIG LOT
HIGH INVENTORY
HIGH FREQUENCY
SMALL LOT
LOW INVENTORY
TKM
Cross dock operation for Milk run system
1
2
3Cross Dock
Sub Route 1Sub Route 3
Sub Route 2
S1
S2
S3S4
S1
S2
S3
S4
S1
S2
S3
Delhi Cross Dock
Main Route
Chennai Cross Dock
Pune Cross Dock
Main Route Main Route
TKM
Cross dock operation for Milk run system
Optimum Route Planning
122cmt
cmt kg route cmt kg type cmt kg %CS011 CHEN W 15.744 5535 1-2 CS01 37 8976 HCV 32 9000 115%CS012 CHEN B 0.131 45JG CHEN B(JG) 1.500 1770CS013 CHEN I 19.500 1627CS021 CHEN BT 9.608 516 1-1 CS02 17.688 1768 LCV 24 4000 74%CS022 CHEN R 8.079 1251CC011 CHEN A 52.722 6571 1-1 CS03 52.722 6571 LDV 55 6800 96%RM CHEN H 0.800 200 - - 0.800 200.0 - - - -RM CHEN A 0.100 20 - - 0.100 20.0 - - - -RM CHEN N 0.100 20 - - 0.100 20.0 - - - -
truck specdayCycroute area supplier
trip
Standardized Truck Timetable
ROUTE NO.
TRUCK TYPE
Place Dist Time T/T
29.Apr 7:3029.Apr 9:00
6km 0.15hrs29.Apr 9:1529.Apr 10:15
1km 0.10hrs29.Apr 10:2529.Apr 10:55
28km 0.40hrs29.Apr 11:3529.Apr 12:35
35km 1.30hrs
HCV
CS01
Cross Dock
4 5 6 7 8
Sup-A 1.00hrs
Sup-B 0.30hrs
Sup-C 1.00hrs
12 13 14 159 10 11
Logistics on fixed time / variable qty basis
High Frequency Delivery
FDelhi & West : 1 times a day
FChennai, South India : 4 times a day
FBangalore : 4 - 16 times a day
Supplier A
Supplier B Supplier C
Supplier D
TKM
LOGISTIC CONTROL IMAGE
TKM
Short-Route
TKM LOGISTICPROVIDER
Volume CalculationReceiving Plan
Central Operation Control
Long-Route
Suppliers
Cross-Dock TKM
Suppliers TKM
TRANSYSTEM
Joint venture between
Mitsui corp. (Japan)
&
TCI (India)
Truck Status Control
FProcedure
Long-Route : Driving-Members call from predefined points
Local-Route : Controlled by Radio-Receiver up to 60km
FVisual Control (Status-Board)
Detect En-route Problems = Never stop the line
Special Design Fleet
Long Deck Sliding Door : 16 (50cmt)
HCV Sliding Door : 10 (32cmt)
LCV Sliding Door : 4 (24cmt)
HCV Gull-Wing : 5 (32cmt)
LCV Gull-Wing : 3 (24cmt)
Side Loading Method
FWing type truck
FSliding door type
FSwing door type
Inventory of far off supplier with Cross dock operations – Delhi & Pune
TKM - Inventory Status
0
1
2
3
4
5
6
7
8
9
ConventionalSystem
SVP TKM Current TMC TKM Future
Stoc
k in
Day
s
-Milkrun pick up of parts.- Transhipment of parts
to Main truck- Truck status control.- Daily arrival of parts
- Frequency increase through Mix Logistics with TKM
Suppliers.- Lot Size reduction
- Double cross docking (Delhi Suppliers)Daily arrival 1 Day
(16 hrs)
Daily arrival 4 Hrs (0.25 days)
Safety Stock 1 Day (16 Hrs )
Safety Stock 6 Hrs (0.3 days)
-Supplier Delivery & Quality
improvement
( Y 2003 ) ( Max 2 Hrs ) (Y 2004 –Oct )( Dec ‘ 99 )
KANBAN SYSTEM
JUST IN TIME
APL STTI TGK DNKI NTTF
KANBAN SORTING ROOM
TKML SUPPLIER
CHECK SHEETAPL 1-2-2KBN NO. QTY111 2222 1333 4XXX Y
1
KANBANPOST
3
6
TIME LOC1LOC2LOC3LOC4
TRUCK1
TRUCK2
TRUCK3
INCOMING KANBAN
8
9
CHECK SHEETAPL 1-2-2KBN NO. QTY111 2222 1333 4XXX Y
KBN 222
KBN 222
2
EMPTY BOX
5
4 7
KBN 222
KBN 222
12
10
11
1 1
11
11
KBN 111
LINESIDE
GRN IN SYS
SUPPLIER LINE SIDE
10
CHECK SHEETAPL 1-2-2K
KBN 222
9
KANBAN OPERATION OVERVIEW
PURA/C
PAYABLE
LOCAL PARTS KANBAN SAMPLE
TKMPART DETAILS :
GLOVE COMPARTMENT
SUPPLIER INFORMATION :TG KIRLOSKAR
T004-A
PROCESS CODE : ASSEMBLY
55581- 0B010- 00QTY/BOX
10
PACKING CODE : PB10123
DOCK 01
LOCATION CODE :T2R-2
516 SEQ NO1
KEY CODE :1234567890
(BANGALORE SUPPLIER CASE OPERATING WITHOUT CROSS DOCK)
PARTS READY FOR DESPATCH AT SUPPLIER SIDE
LOADING / UNLOADING USING FORK LIFT
LABELS FACING OUTSIDEPARTS PALLETISED
Parts stacking at PC Zone ready for in-house logistics:
•Parts are stored at PC Zone at predefined locations Line wise orprocess wise.
Inventory of Bangalore supplier ( No Cross dock operations)
TKM - Inventory Status
0
1
2
3
4
5
6
7
8
9
Conventional System TKM Current TMC
Stoc
k in
Day
s
Kanban System-1~ 16 delivery / day
- Truck status control by wireless – Time
control- Frequency increase with Mix logistics of
TKM SuppliersSafety Stock Avg 6 Hrs (0.3 days)
Safety Stock Avg4 Hrs (0.25 days )
( Y 2003 )
Avg 2 Hrs
JUMBIKI SYSTEM
( Sequential Procurement )
JUST IN TIME
JUST IN TIMEJumbiki System
• System to supply Parts directly from supplier to Assembly line according to sequence of production.
• Suitable for bulky Parts with more variants & supplied by nearby supplier
e.g- Seats, Door Trims, Carpets (Araco)
• System for total elimination of Inventory.
CENTRAL CONTROL ROOM (CCR)
JUMBIKI SYSTEM
Line In - Based on Production Leveling
ASSEMBLY LINE
Information to CCR
Fax to Supplier
Preparation at Supplier & Transport to TKM
Assembly
Receiving andSupply to Line
Pre defined Time Scale based on tact time
CONVENTIONAL SYSTEM
A1
A2
A3 A3
A2 A2
A3
A1 A1 B1
B2
B3 B3
B2 B2
B3
B1 B1 C1
C2
C3 C3
C2 C2
C3
C1 C1
Stock of each set
For Model A
AssemblyLine
For Model B For Model C
Model A Model CModel B
AssemblyLine
Seats received from supplier in sequence of Production Plan
TPS
JUMBIKI
Model A Model CModel B
B3
B2
B1
A2
A3
A1
JUMBIKI SYSTEM
JUMBIKI PARTS RECEIVED
JUMBIKI SEAT AT LINE SIDE
IN-HOUSE
LOGISTICS
JUST IN TIME
JUST IN TIME
WELDING SHOP
INHOUSE LOGISTICS (Chorukyu System)
CONVENTION SYSTEM TKM SYSTEM
A1
ManufacturingManufacturing
TPS
A2 A3 A4
A5 A6 A7 A8
A5
A1 A2 A3 A4
A6 A7 A8
(SMALL LOT SUPPLY)INHOUSE LOGISTICS
SEQUENTIAL SUPPLY SYSTEMINHOUSE LOGISTICS – ASSEMBLY SHOP
SEQUENTIAL SUPPLY SYSTEM
INHOUSE LOGISTICS – ASSEMBLY SHOP
SUPER FLEXIBLE ASSEMBLY LINESUPER FLEXIBLE ASSEMBLY LINE
TKM IS CHALLENGING NEW CONCEPT OF SUPER FLEXIBLE LINE TKM IS CHALLENGING NEW CONCEPT OF SUPER FLEXIBLE LINE
THAT IS MIXED PRODUCTION OF MPV (frame model) AND THAT IS MIXED PRODUCTION OF MPV (frame model) AND PASSENGER CAR (monocock model) ON SINGLE PRODUCTION LINE, PASSENGER CAR (monocock model) ON SINGLE PRODUCTION LINE,
BY QUICK LAUNCHING OF NEXT MODEL ON THE EXISTING BY QUICK LAUNCHING OF NEXT MODEL ON THE EXISTING PRODUCTION LINE. PRODUCTION LINE.
KAIZEN
(CONTINUOUS IMPROVEMENT)
Kaizen based on practice of manufacturingKaizen based on practice of manufacturing
Before After
•FIFO not followed•Mikara not established•Unsafe movement of F/L
•FIFO achieved •Mikara established• F/L movement standardized
Shooter system to maintain perfect FIFOShooter system to maintain perfect FIFO
Pallet, Dolly, Flow rack to reduce handlingPallet, Dolly, Flow rack to reduce handling
•Double handling of Parts•Generates waiting time•Fatigue while parts picking
•Direct supply of parts•zero waiting time•Workability improved•Space reduced (210 Sq.mt)
Before After
Kaizen based on practice of manufacturingKaizen based on practice of manufacturing
Combined LogisticsCombined LogisticsKaizen based on practice of manufacturingKaizen based on practice of manufacturing
Kaizen based on practice of manufacturingKaizen based on practice of manufacturing
Collapsible - Returnable packing
The space saved by this kind of packing is used to transport service parts to dealers
on the return journey
1 Plastic Caps of hoseflexible eliminated
2
Achieved 99%returnable packaging
Kaizen based on practice of manufacturingKaizen based on practice of manufacturingKaizen in packing areas
FUTURE DIRECTION
TKM in-house operations
PC ZONE
W
P
T
A
Kanban Room
S8
S9
S10
S11
S12
S1
S2
S3
S4
S5
In-house Bar Coded
Kanban
Store Cards
Receive Material
Insert cards
Store Parts
TKM e Kanban information to
Suppliers/ Cross Dock
S8 S9 S10
S11
S12
S1 S2 S3
S4 S5
CROSS DOCK
Download Kanban data
Cross Dock operations
S8 S9 S10
S11
S12
S1 S2 S3 S4 S5
SUPPLIER
Download Kanban
data
Supplier operations
SERVICE PROVIDE
R
SERVICE PROVIDE
RCROSS DOCK
CROSS DOCK
E E -- KanbanKanban
Increase frequency
Reduce lot size
Mixed Logistics Concept
Purpose:
1) Share logistics between TKM & Supplier.
2) Reduce lot, increase delivery frequency and finally reduce inventory.
3) Reduce transportation cost.
4) Mutual development and benefit between TKM & supplier.
Mixed Logistics1st Step
Mixed Logistics Image
TKM - TKAP Mixed Logistics
Example
We live in an age of constant change
‘Today's perfection is tomorrows ‘Today's perfection is tomorrows mediocritymediocrity’’
We need to realise & improve
Closing wordClosing word
THANK YOU FOR YOUR ATTENTION