Page 445 - The Toyota Way Fieldbook
P. 445

Toyota  Indiana  2 Production  Shift  775 Vehicles  per day  8 X Daily  Shipping  Staging  Production Lead Time  8.5 Days  Processing Time @  159 Secs.









          Forecast  Daily  Orders            35  35  35

                                           35

                                                                                1.5 Days
                     Order

                     Daily
          Production Control  MRP           35  Assembly &  Secondary  Assembly  X 9 Operators  C/T - 65 Secs.  C/O - 15 Mins.  Scrap - .75%  Overtime -<1  Hour/Day  65 Secs.







                     Purch.  Parts
                                                                 Max: 3 Boxes          Toyota 500N center cell future state fourth quarter 2004

                                             Totes             FIFO

                               Coil                                             5 days
           Forecast                          2 Days    5 Days  2 Days

               Daily  Orders                Batch

                                      Tube Bending  Process  C/T - 30 Secs.  C/O - 15 Mins.  Stamping  Process  C/T - 2 Secs.  C/O - 30 Mins.  Purchase Parts  Outside Processes  MRP  Spun Res.  Process  C/T - 62 Secs.  C/O - 0  94 Secs






           Suppliers  Purchase Parts,  Steel, Raw Pipe  5 X Week   Pipe  2 Days  Steel  Coils  1 Days  Pipe  2 Days  2 days  Figure 19-8.
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