Page 442 - The Toyota Way Fieldbook

2 Separate Plants
Customer
2 Shifts
Toyota
Forecast
Orders
Daily
Orders
Daily
Pacesetter
Schedule
Level
Production Supervison
Production Control
Weekly Schedule
MRP
Lean Bascis Daily Ship Schedule -EPEI -Line Balance -S/W -Layout 8 X Daily Balance Work to eliminate secondary assembly Assembly Secondary Assy. Shipping X 16 Opers. Bolt- Up Process C/T - 52 Secs. C/O - 1 Hour C/T - 48 Secs. Scrap - 4% of Sales SMED Assy. Overtime - 4 Hrs. per C.over day Target Cell Reduce
4 Days 5 Days 4 Days 1.5 Days 5 days
Forecast Add press to F/B delivery route Implement timed Material deliveries Create container Kanban
2.5 X / Week Weekly Schedule
Tube Bending Process C/T - 30 Secs. C/O - 15 Mins. Press Process C/T - 2 Secs. C/O - 1 Hour Purchase Outside Sources Spun Res. Process C/T - 62 Secs. C/O - 0 94 Secs

Suppliers Purchase, Steel. Pipe 5 X Week Pipe 2 Days Steel 2 Days Introduce Weekly Kanban Purchase 4 Days Supplier Pull 4 Days 4 days Figure 19-7.