[HN Gopher] The Toyota Production System ___________________________________________________________________ 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. ___________________________________________________________________ (page generated 2021-01-03 23:00 UTC)