Toyota Manufacturing
Toyota Motor Manufacturing Case
Problem Identification
In 1992 Toyota Motor Manufacturing USA, Inc. (TMM) saw significant problems with defective seats that resulted in a compromise of Toyota’s lean manufacturing system. This problem stemmed from a couple of major deviations from Toyota’s standardized production system (TPS). This problem was initially caused by a change in world market demand for variations of seats and TMM’s facility being made the sole manufacturer of the Toyota Camry Wagon. Toyota faced significant production issues in the wake of the proliferation of these seats. Toyota’s production facility quickly amassed a total of over 30 variations of seats. This was a change from the previous number of 8 variations.
Analysis
In April 1992, Toyota’s run ratio dropped from 95% to 85%. This ratio represented the amount of cars that potentially could have been produced by Toyota under ideal circumstances. This change resulted in 45 less cars being......
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