Toyota Case

)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 ... Showed first 120 words of 1336 Size (words) ...

Continuing with last 115 out of 1336 Size (words) ...inevitable they would crop up constantly, in turn making deviations from planned operating conditions unavoidable. Any departure from the aforementioned method of handling exposed problems would paralyze the plant, leading to problems like that of the defective seats, hence the need for exercises such as the Five Whys. These problems caused a 10 percent drop off in run ratio from 95 percent to 85 percent which is very significant which causes a shortfall of 45 cars per shift thus making overtime a necessity to meet there goals. TMM would have a hard time succeeding if this problem continues to impede their production rates and a solution needs to be worked out quickly and efficiently.