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1、,A Brief History of Car Manufacturing Invention of Automobile in 1880 The Henry Ford Mass Production System The Toyota or Lean Production System,Toyota Production System,Toyota Production System,Carl Benze,Gotlib Daimler,Invention of Automobile Carl Benz is generally given credit to develop world fi
2、rst automobile in 1985 Gotlib Daimler is also contemporary of Carl Benz who is simultaneously developed the automobile with him. Other contemporaries are Wilhelm Maybach and Seigfried Marcus known for developing automobile later during the same period.,Toyota Production System,Carl Benze,Gotlib Daim
3、ler,Replica of the Benz Patent Motorwagen built in 1886,Toyota Production System,Carl Benze,Gotlib Daimler,Carl Benze First Motorcyle,Toyota Production System,Carl Benze,Gotlib Daimler,Toyota Production System,Carl Benze,Gotlib Daimler,Carl Benze “Vilo” Model of 1894,Henry Fords Mass Production Syst
4、em In 1910 Henry Ford laid the foundation of first highly organized assembly line system of automobile manufacturing. He organized all the elements of a manufacturing system- people, machines, tooling, and products- and arranged them in a continuous system called conveyer system for manufacturing th
5、e Model-T automobile. Ford was so incredibly successful he quickly became one of the worlds richest men and put the world on wheels. Ford Motor Company produced “A-Bomber an Hour” during WWII for USAF using the same concept.,Toyota Production System,Ford Motor Companys Production Lines,Toyota Produc
6、tion System,Henry Ford Introduced Conveyer Belt System in Automotive Industry,Toyota Production System,A bomber an hour: Assembly in Ford Motor Company B-24 bomber final assembly area at Ford Motor Companys Willow Run plant,Toyota Production System,Toyoda Family in Auto Industry The Allied victory a
7、nd the massive quantities of material behind it (“A Bomber an Hour” success) caught the attention of Japanese industrialists. Toyoda family were among those Japanese industrialists who were observing American industrial strength and wanted to emulate it by investing in Automotive Industry. Toyoda Au
8、tomatic Loom Company, under the encouragement of the Japanese government, which needed domestic vehicle production partly due to the worldwide money shortage and partly due to the war with China The Toyota Motor Corporation was founded in September 1933 when Toyoda Automatic Loom created a new divis
9、ion devoted to the production of automobiles under the direction of the founders son, Kiichiro Toyoda.,Toyota Production System,Kiichiro Toyoda,The first production model AA in 1936,Toyota Learns From the Ford Motor Company Toyota found it difficult to emulate Ford Motor Company whose production sys
10、tem was based on Mass Production System. Post WWII Japanese economy was in shambles and Toyota could not afford Mass Production of vehicles due to smaller market size. Toyotas top bosses begin to design a whole new concept of Production System which is now also known as Just-in-Time system.,Toyota P
11、roduction System,At Toyota Motor Company, Taichii Ohno and Shigeo Shingo, are known as the brain behind transforming Ford production and other techniques into an approach called Toyota Production System or Lean Production System or Just-in-Time System. Taichii Ohno was the Production Boss of Toyota
12、Motor Corporation and Shigeo Shigo was industrial engineer and consultant of Toyota Motor Corporation.,Toyota Production System,Taichii Ohno,Shigeo Shingo,Ford vs. Toyota model of Production System Can be best explained as: Mass Production vs. Lean (JIT) Production,Toyota Production System,What is M
13、ass Production System Mass production is the name given to the method of producing goods in large quantities at low cost per unit. This system of production is also known as Push System or Just-in-Case System. To make it worthwhile, mass production requires mass consumption. With precision equipment
14、, large numbers of identical parts could be produced at low cost and with a small work force.,Toyota Production System,What is Lean Production System? Lean Production System is the system designed and evolved in Toyota Motor Corporation. It is the modified form of Henry Fords Mass Production System.
15、 In some areas its philosophy seem exactly opposite to the fundamental principles of Mass Production System. This system is generally known as JIT system, which in fact is an important pillar of Lean Production System. The slogan of Lean Production is “Less is best”,Toyota Production System,Toyota P
16、roduction System,Toyota Production System,Just-in-Time Leveled Production Pull System Continuous Flow Processing Takt Time Flexible Work Force 3 Ms 5 S,Standardized Work Kaizen (Continuous Improvement),Jidoka (Automation) Andon-Fixed Position Stop System Pokayoke- Fail Proofing System,Just-in-Time (JIT) System Just-in-Time means PRODUCING: a) Only what is needed b) in necessary quantity c) at necessary time,Toyota Production System,Main Components of JIT Leveled Production Pull Syst
