Self Adjusting to Product Variations with Multipurpose Machine

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When considering the fabrication machinery or equipment actually, to conflict between product variety and production. If we do not produce many kinds of products, special equipment for mass production for example is usually a powerful weapon to reduce costs. However, at the Toyota there are various types of cars that are distinguished in various combinations based on type, tires, options, colors and others. For example, three or four thousand types of corona, actually produced. To carry out production lancar with various types of similar products, needed a useful machines or flexible. By adding certain instruments and tools on these machines, Toyota has set a production process to accommodate the general usability.

Production According to Market Demand

Production launch is the most important requirement for production with Kanban and to minimize the idle time in terms of manpower, equipment and goods in process. smoothing production is the cornerstone of the Toyota production system.

As previously mentioned, every process goes into the process earlier to take the necessary goods at the time required in the necessary quantities. With that kind of production arrangement, if the next process to take spare parts are fluctuating in terms of time or number, then the previous process have to prepare supplies, equipment, and labor amount needed to adjust to peak variation of the amount requested.

Toyota Production system : Determine Daily Production Order

For example there is a production line is expected to produce 10,000 cars type A in 10 working days, 8 hours each, within a month. 10,000 cars type A consists of the 5,000 cars, 2,500 hardtop, and 2,500 wagons. If these values are divided by 20 working days, obtained 250 sedan, 125 hardtop, and 125 wagons per day. This is pelancaran production in terms of average daily amount of each type of cars manufactured.

In a turn (shift) operations during the eight-hour (480 minutes), have produced 500 units. Therefore, the unit cycle time, or mean time needed to produce one vehicle of any kind, is 0.96 minutes (480/500) or about 57.5 seconds.

The right mix or production sequence can be determined by comparing the actual cycle time to produce a particular model of car type A. For example, the maximum time to produce a sedan type A is determined by dividing the time shift (480 minutes) by the number of sedans that will be produced during that turn (250); in this sense, the maximum time is 1 minute 55 seconds. This means that the cycle time for a sedan is 1 minute 55 seconds.


When comparing this interval with average cycle time by 57, 5 seconds, it is obvious that another car of any kind can be produced between the time a sedan completed and the time when other sedans have produced. Thus, the basic production sequence is the sedan, another vehicle, sedan, another vehicle, and so on.

Maximum time to produce a single wagon or a hardtop is 3 minutes 50 seconds (480/125). If these values are compared with the magnitude of cycle time 57.7 seconds, it is obvious that the three cars of any kind can be produced between each wagon or hardtop. If in the production of a wagon that followed the first sedan, the production sequence is the sedan, wagon, hardtop, sedan, wagon, hardtop, etc..Here is an example pelancaran terms of production cycle time each type.

Learn More about 5s Management & Lean Manufacturing

TPS principle: Self Adjust to a Changing Number of Production Change

Let us consider the adjustment of production by using Kanban. Suppose a machine fabrication process should produce 100 engines per day. The next process, with Kanban-making, asking for five machines per one lot. Lot-lot was then drawn 20 times per day, in order to reach exactly 100 the number of machines produced each day.

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With a production plan like this, if there is a need to reduce all of the production process by 10 percent as the adjustment procedure, the final process in this example should take the machine 18 times per day. Then, because the machine only produces 90 units a day, the time left for the 10 units will be saved by stopping production of this process. On the other hand, if there is a need to increase total production by 10 percent, the final process should take the machine 22 times per day with Kanban it.Then the previous process must produce 110 units, an additional 10 units could be covered through overtime.