[HN Gopher] The Toyota Production System
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The Toyota Production System
Author : louis-paul
Score : 77 points
Date : 2021-01-03 11:19 UTC (11 hours ago)
(HTM) web link (blog.toyota.co.uk)
(TXT) w3m dump (blog.toyota.co.uk)
| nateberkopec wrote:
| If you produce physical goods of any kind, Shigeo Shingo should
| absolutely be required reading. His ideas around quality control
| and setup times still sound revolutionary even now.
| eesmith wrote:
| Can anyone comment here on the "Uddevalla concept"? Quoting
| https://ideas.repec.org/p/pra/mprapa/10785.html :
|
| > Both researchers and practitioners in industrial organization
| ask themselves today whether lean production is the only possible
| model for the future. Enriching Production proposes a radically
| different alternative, which was put into practice at Volvo's
| Uddevalla plant during its brief life span.
|
| The book "Enriching Production" is at https://mpra.ub.uni-
| muenchen.de/10785/1/MPRA_paper_10785.pdf .
|
| As I have no experience with lean nor with automotive production
| history, I find it hard to interpret.
| neves wrote:
| I've lost my faith in all this Just int Time marketing stuff. I
| tried to buy a specific Toyota car in Brazil and they said that
| it would take 6 months to get me one. I don't know which kind of
| legal bureaucracy created this, but I went with a Honda.
| [deleted]
| pulse7 wrote:
| If you want to buy a >>specific<< configuration of any brand,
| you will have to wait for months - even for Honda...
| CamperBob2 wrote:
| More important to the consumer, JIT often means waiting weeks
| for replacement parts to be back-ordered several levels up the
| chain. It's a mistake to think there are no downsides to this
| methodology.
|
| Ultimately JIT manufacturing should be seen for what it is:
| central planning in action. Good for the central planners,
| certainly, but not for the end users.
| mschuster91 wrote:
| Following JIT practices in production does not mean that one
| has to abolish spare parts storage.
|
| The only ones known to have _massive_ problems with spare
| part supply issues is Tesla, which is a contributing factor
| in their high insurance rates (e.g. per
| https://electrek.co/2017/06/05/tesla-owners-insurance-
| rates/).
| adingus wrote:
| JIT doesn't mean you should carry no inventory or wait for
| orders. You should carry enough stock that you sell out of
| just in time for the replenishment to arrive.
| mschuster91 wrote:
| The practical implementation of JIT production is to get
| rid of (expensive) warehouses and instead have rolling
| trucks on streets be the warehouse - you need the trucks
| anyway to transport stuff, but now you don't have to pay
| for the space as roads are owned by the public.
| drewcoo wrote:
| Sounds like the drug dealer model, where product is
| largely delivered to customers as they need it. Large
| stashes of drugs have additional potential downside,
| making the model more attractive than normal.
| eatonphil wrote:
| I highly recommend the books "Toyota Production System" and "The
| Machine That Changed The World" for a background on the
| manufacturing cousin/ancestor of agile software development.
|
| I wish there were newer studies though that cover the rise of
| Hyundai/Kia quality in the last two decades. If you know of any
| please let me know.
| DubiousPusher wrote:
| Absolutely mind blowing to watch that transformation. And not
| just in durability and features but in aesthetics as well. A
| BMW interior is still a BMW interior but the interior of a 2020
| Hyundai is much closer to the interior of a 2020 BMW than the
| interior of a 2002 Hyundai was to the interior of a 2020 BMW.
|
| This is one are where others impress as well. Even GM and Ford
| have come far in this regard.
| mixmastamyk wrote:
| Guessing that last 2020 was supposed to be a 2002?
| Judgmentality wrote:
| > I wish there were newer studies though that cover the rise of
| Hyundai/Kia quality in the last two decades.
|
| I realize this is a tangent, but the fact that Hyundai managed
| to build this and sell it with a 10 year warranty is
| incredible.
|
| https://www.youtube.com/watch?v=uhsgdwUX1-w
| LeifCarrotson wrote:
| Recently read "The machine that changed the world", and I too
| wish there was a more recent study. I've worked in several
| Michigan and Indiana tier 1s and OEM plants, and seen some of
| the differences described, but the book is 30 years old now.
| The fundamentals are still fundamental, and culture change is
| really, really slow, but everyone's making improvements.
| m3kw9 wrote:
| Notice the blurred pics being presented as motion blur trying to
| do seal "secrets"
| neom wrote:
| As a huge Ed Deming fan, I'd recommend these books:
|
| - The Essential Deming: Leadership Principles from the Father of
| Quality: https://www.amazon.com/Essential-Deming-Leadership-
| Principle...
|
| - The New Economics for Industry, Government, Education:
| https://www.amazon.com/Economics-Industry-Government-Educati...
|
| - The Toyota Way: 14 Management Principles from the World's
| Greatest Manufacturer: https://www.amazon.com/Toyota-Way-
| Management-Principles-Manu...
|
| Deming is really a great thinking in the area of product
| development and agile methodologies.
| vvanders wrote:
| Another great perspective is This American Life's episode on
| the NUMMI plant[1]. Coming full circle from Deming back to GM.
|
| [1] https://www.thisamericanlife.org/561/nummi-2015
| petra wrote:
| I haven't listened to the podcast yet, so - why NUMMI we're
| not able to copy the Toyota production system - given that
| Toyota has sent them experienced advisors ?
| DubiousPusher wrote:
| They did actually. I can't remember why specifically they
| closed the plant in the end. But one of the overriding laws
| of global capitalism is that it's possible to do everything
| right but and still lose cause of a trade deal or an
| acquisition or a global recession or...
| dharmab wrote:
| NUMMI was a success, but that success was not replicated at
| other GM plants. NUMMI closed during the recession as GM
| discontinued brands like Pontiac due to severely reduced
| demand.
|
| Today a large part of the land is a Tesla factory.
| vvanders wrote:
| Yeah, they cover it pretty well in the podcast. By the
| numbers NUMMI did well however to achieve those figures
| they upended many traditional roles and couldn't get the
| leadership in GM to get on board.
|
| There's a great little footnote at the end of the podcast
| about a small upstart company buying the plant with the
| vision of building electric cars in the future.
| wpietri wrote:
| Seconded. It's such a good portrait. The way the workers
| talked about the change sticks with me years later.
|
| Adding to the recommendations, I found Rother's _Toyota Kata_
| very valuable in understanding how to make Lean approaches
| work: https://en.wikipedia.org/wiki/Toyota_Kata
|
| For applying it in software, I loved Mary Poppendieck's
| books, which are listed about half-way down the page here:
| http://www.poppendieck.com/
|
| And for the math-inclined, Reinertsen's "Principles of
| Product Development Flow" is very insightful:
| https://www.amazon.com/Principles-Product-Development-
| Flow-G...
| mcot2 wrote:
| There are a lot of amazing concepts that Toyota developed. It
| requires a lot of discipline, focus and commitment to implement
| properly.
|
| One thing I didn't see mentioned that Tesla is currently doing is
| a very strong relationship between design and production. The
| upcoming Cybertruck for example doesn't have paint and it has an
| exoskeleton design that should be much easier to produce. Over
| the years I have not seen any radical designs from Toyota that
| suggest that the ease of production was influencing radical
| design choices.
| throwaway0a5e wrote:
| Designing for production became highly unfashionable because
| the big three did it extensively in the 1970s and 1980s
| resulting in very efficient production of cars nobody wanted.
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