Toyota productivity
12-26-12 | 05:57 AM
#1
Toyota productivity
Older article but interesting.
TOYOTA PRODUCTIVITY
Toyota's 2010 capacity: 9.31 million vehicles. It takes Toyota two years to develop a car compared to four to six years for other companies. Amazingly different models can be produced on the same assembly line.
The Toyota Production System, (TPS) was described by an MIT study as “the Machine That Changed the World.” It aims to eliminate waste, reduce defects, maximize flow, and increase efficiency and productivity by employing a "unique production system that cuts costs through continuous improvement, yielding sharp reductions in product development and manufacturing lead times.” The use of the "platform team" approach unites managers in disparate areas.
Toyota factories are highly automated. They feature electrified paint baths and computer guided driverless carts that deliver parts. Each worker has the power to shut down the assembly line if a defect is found, with the defect being corrected when it is found. Under the old Western method, defects were repaired later.
In 2005, Toyota was named North America’s most efficient manufacturing operation by the closely-watched Harbour Report. It takes the company just 27.9 hours to produce the average car or truck. By contrast GM, Ford and Chrysler take between 34 and 37 hours to make a vehicle.
Toyota keeps getting more efficient and productive. Using impute from workers in eight countries, the development time for the latest Camry was 17 months compared to 23 months for the previous model. The Toyota plant in Kentucky that makes it needed only 15 days to retool to rather than 45 days for the previous model.
Toyota is trying hard to cut cost in face of rising cost for steel and other materials and increasing competition. Even before the global financial crisis in 2008 and 2009 it was trying to cut costs by $3 billion a year, a process likened to squeezing moisture from a dirty dusting cloth.
In January 2011 Toyota opened a new plant to make compact cars in Ohira, Miyagi Prefecture—its first new Japanese plant in 18 years— only to have it shut down a few weeks later by the earthquake and tsunami in 2011. Miyagi Prefecture was hit hard by the disaster.
http://factsanddetails.com/japan.php?itemid=927
TOYOTA PRODUCTIVITY
Toyota's 2010 capacity: 9.31 million vehicles. It takes Toyota two years to develop a car compared to four to six years for other companies. Amazingly different models can be produced on the same assembly line.
The Toyota Production System, (TPS) was described by an MIT study as “the Machine That Changed the World.” It aims to eliminate waste, reduce defects, maximize flow, and increase efficiency and productivity by employing a "unique production system that cuts costs through continuous improvement, yielding sharp reductions in product development and manufacturing lead times.” The use of the "platform team" approach unites managers in disparate areas.
Toyota factories are highly automated. They feature electrified paint baths and computer guided driverless carts that deliver parts. Each worker has the power to shut down the assembly line if a defect is found, with the defect being corrected when it is found. Under the old Western method, defects were repaired later.
In 2005, Toyota was named North America’s most efficient manufacturing operation by the closely-watched Harbour Report. It takes the company just 27.9 hours to produce the average car or truck. By contrast GM, Ford and Chrysler take between 34 and 37 hours to make a vehicle.
Toyota keeps getting more efficient and productive. Using impute from workers in eight countries, the development time for the latest Camry was 17 months compared to 23 months for the previous model. The Toyota plant in Kentucky that makes it needed only 15 days to retool to rather than 45 days for the previous model.
Toyota is trying hard to cut cost in face of rising cost for steel and other materials and increasing competition. Even before the global financial crisis in 2008 and 2009 it was trying to cut costs by $3 billion a year, a process likened to squeezing moisture from a dirty dusting cloth.
In January 2011 Toyota opened a new plant to make compact cars in Ohira, Miyagi Prefecture—its first new Japanese plant in 18 years— only to have it shut down a few weeks later by the earthquake and tsunami in 2011. Miyagi Prefecture was hit hard by the disaster.
http://factsanddetails.com/japan.php?itemid=927
12-26-12 | 07:46 AM
#2
Racer
Joined: Jan 2007
Posts: 1,936
Likes: 0
From: CA
Of course they can shave 2 years off development time when they don't have to develop anything. Just wait until BMW comes up with iDrive system and steal it, save a year right there. 
Just wait until Audi comes up with a new design and copy it, shave off another year production time right there, also save waste by not haviing to use any clay or paper for coming up with anything original. 
Floor mats slipping? Who cares...sell it right now and save cost, recall later if caught.
Car crumbles like a soda can in new crash tests? Who gives a damn, sell it right now and save time, redesign later if IIHS finds out.
Just wait until Audi comes up with a new design and copy it, shave off another year production time right there, also save waste by not haviing to use any clay or paper for coming up with anything original. Floor mats slipping? Who cares...sell it right now and save cost, recall later if caught.
Car crumbles like a soda can in new crash tests? Who gives a damn, sell it right now and save time, redesign later if IIHS finds out.
Last edited by Stormwind; 12-26-12 at 07:55 AM.
12-26-12 | 08:36 AM
#3
Lexus Champion
Joined: Jan 2005
Posts: 19,964
Likes: 179
Of course they can shave 2 years off development time when they don't have to develop anything. Just wait until BMW comes up with iDrive system and steal it, save a year right there. Just wait until Audi comes up with a new design and copy it, shave off another year production time right there, also save waste by not haviing to use any clay or paper for coming up with anything original.
Floor mats slipping? Who cares...sell it right now and save cost, recall later if caught.
Car crumbles like a soda can in new crash tests? Who gives a damn, sell it right now and save time, redesign later if IIHS finds out.
Just wait until Audi comes up with a new design and copy it, shave off another year production time right there, also save waste by not haviing to use any clay or paper for coming up with anything original. Floor mats slipping? Who cares...sell it right now and save cost, recall later if caught.
Car crumbles like a soda can in new crash tests? Who gives a damn, sell it right now and save time, redesign later if IIHS finds out.
12-26-12 | 10:25 AM
#4
Lexus Test Driver
Joined: Apr 2008
Posts: 1,363
Likes: 2
From: Ontario
Of course they can shave 2 years off development time when they don't have to develop anything. Just wait until BMW comes up with iDrive system and steal it, save a year right there. Just wait until Audi comes up with a new design and copy it, shave off another year production time right there, also save waste by not haviing to use any clay or paper for coming up with anything original.
Floor mats slipping? Who cares...sell it right now and save cost, recall later if caught.
Car crumbles like a soda can in new crash tests? Who gives a damn, sell it right now and save time, redesign later if IIHS finds out.
Just wait until Audi comes up with a new design and copy it, shave off another year production time right there, also save waste by not haviing to use any clay or paper for coming up with anything original. Floor mats slipping? Who cares...sell it right now and save cost, recall later if caught.
Car crumbles like a soda can in new crash tests? Who gives a damn, sell it right now and save time, redesign later if IIHS finds out.
12-26-12 | 11:02 AM
#5
Pole Position
Joined: Jan 2006
Posts: 2,800
Likes: 7
From: UK
12-26-12 | 11:35 AM
#6
Pole Position
Joined: May 2004
Posts: 2,602
Likes: 88
From: Singapore
Of course they can shave 2 years off development time when they don't have to develop anything. Just wait until BMW comes up with iDrive system and steal it, save a year right there. Just wait until Audi comes up with a new design and copy it, shave off another year production time right there, also save waste by not haviing to use any clay or paper for coming up with anything original.
Floor mats slipping? Who cares...sell it right now and save cost, recall later if caught.
Car crumbles like a soda can in new crash tests? Who gives a damn, sell it right now and save time, redesign later if IIHS finds out.
Just wait until Audi comes up with a new design and copy it, shave off another year production time right there, also save waste by not haviing to use any clay or paper for coming up with anything original. Floor mats slipping? Who cares...sell it right now and save cost, recall later if caught.
Car crumbles like a soda can in new crash tests? Who gives a damn, sell it right now and save time, redesign later if IIHS finds out.
The dual injection system in the GR-FSE series of engines are the first widespread use of direct injection that doesn't have the problem of carbon buildup due to the concomitant use of port injection. These engines came out in 2005/6, have rock solid reliability and only recently have the Germans been able to build engines which rival it in terms of specific horsepower and fuel efficiency and they've done that at the cost of turbo-lag.The Germans have fallen back on an almost centuries old tech--turbocharging which compromises pure driver appeal due to lag.
The almost all carbon fiber LFA. BMW/MB/Audi don't have anything that rivals it on the Nurburgring even now.
For a longtime poster on CL, you don't seem to know any major innovations by Toyota/Lexus. Either that or you have a problem with selective memory.
12-26-12 | 12:13 PM
#7
Lexus Champion
Joined: Feb 2011
Posts: 3,309
Likes: 31
From: Canada
Of course they can shave 2 years off development time when they don't have to develop anything. Just wait until BMW comes up with iDrive system and steal it, save a year right there. Just wait until Audi comes up with a new design and copy it, shave off another year production time right there, also save waste by not haviing to use any clay or paper for coming up with anything original.
Floor mats slipping? Who cares...sell it right now and save cost, recall later if caught.
Car crumbles like a soda can in new crash tests? Who gives a damn, sell it right now and save time, redesign later if IIHS finds out.
Just wait until Audi comes up with a new design and copy it, shave off another year production time right there, also save waste by not haviing to use any clay or paper for coming up with anything original. Floor mats slipping? Who cares...sell it right now and save cost, recall later if caught.
Car crumbles like a soda can in new crash tests? Who gives a damn, sell it right now and save time, redesign later if IIHS finds out.
In case you haven't noticed, the computer interface systems in Toyota and Lexus cars are completely different from iDrive.
The dual injection system in the GR-FSE series of engines are the first widespread use of direct injection that doesn't have the problem of carbon buildup due to the concomitant use of port injection. These engines came out in 2005/6, have rock solid reliability and only recently have the Germans been able to build engines which rival it in terms of specific horsepower and fuel efficiency and they've done that at the cost of turbo-lag.The Germans have fallen back on an almost centuries old tech--turbocharging which compromises pure driver appeal due to lag.
The almost all carbon fiber LFA. BMW/MB/Audi don't have anything that rivals it on the Nurburgring even now.
For a longtime poster on CL, you don't seem to know any major innovations by Toyota/Lexus. Either that or you have a problem with selective memory.
The dual injection system in the GR-FSE series of engines are the first widespread use of direct injection that doesn't have the problem of carbon buildup due to the concomitant use of port injection. These engines came out in 2005/6, have rock solid reliability and only recently have the Germans been able to build engines which rival it in terms of specific horsepower and fuel efficiency and they've done that at the cost of turbo-lag.The Germans have fallen back on an almost centuries old tech--turbocharging which compromises pure driver appeal due to lag.
The almost all carbon fiber LFA. BMW/MB/Audi don't have anything that rivals it on the Nurburgring even now.
For a longtime poster on CL, you don't seem to know any major innovations by Toyota/Lexus. Either that or you have a problem with selective memory.
Toyota's parallel/serial hybrid system with its Power Split Device has already been mentioned. Ford decided to license Toyota's technology -- despite the fact that they developed it completely separately from Toyota -- to avoid any risks that Toyota may accuse Ford of stealing technology.
Toyota's VVT-i is also Toyota's technology that has been patented. Toyota would not have been able to get the patent if it had copied BMW or Audi or Mercedes-Benz.
And looking back a number of years at crash test ratings, yes, the Germans and Volvo have always done well, and the other 2 automakers that did well? It was NOT Honda. Honda has only started to do well recently. It was Toyota and Ford. Toyota has been doing well all along and it is only this very recent, new, 25% offset test that Toyota has not done well in.
Toyota's GR line of engines may be "OLD" but it is still at the top of its game and is still a very efficient engine, even without "new" technologies like Valvematic (continuously variable valve timing and valve lift) and direct fuel injection. Others have had to resort to these new technologies to become as good as Toyota's lines of ZR, AR and GR engines.
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12-26-12 | 01:04 PM
#8
Racer
Joined: Jan 2007
Posts: 1,936
Likes: 0
From: CA
The dual injection system in the GR-FSE series of engines are the first widespread use of direct injection that doesn't have the problem of carbon buildup due to the concomitant use of port injection. These engines came out in 2005/6, have rock solid reliability and only recently have the Germans been able to build engines which rival it in terms of specific horsepower and fuel efficiency and they've done that at the cost of turbo-lag.The Germans have fallen back on an almost centuries old tech--turbocharging which compromises pure driver appeal due to lag.
But regardless of how boring it is any risk of drowsyness will be shocked wide awake when the gas paddle sticks and you realize the car ain't gonna hold up well in a crash.
But don't worry, when the front end twists like a pretzel you still can escape from the trunk right. Then you realize they cut corner on the handle release. Now u really stuck. 
Last edited by Stormwind; 12-26-12 at 01:07 PM.
12-26-12 | 04:20 PM
#10
Lexus Champion
Joined: Jan 2005
Posts: 19,964
Likes: 179
That sounds real great and exciting...on paper. Until you see the final product and realize how boring it is as they don't do much when they get hit by recall after recall (engine oil sluge recall anyone?).
But regardless of how boring it is any risk of drowsyness will be shocked wide awake when the gas paddle sticks and you realize the car ain't gonna hold up well in a crash. But don't worry, when the front end twists like a pretzel you still can escape from the trunk right. Then you realize they cut corner on the handle release. Now u really stuck.
But regardless of how boring it is any risk of drowsyness will be shocked wide awake when the gas paddle sticks and you realize the car ain't gonna hold up well in a crash.
But don't worry, when the front end twists like a pretzel you still can escape from the trunk right. Then you realize they cut corner on the handle release. Now u really stuck. lol.
12-27-12 | 02:21 AM
#11
Pole Position
Joined: May 2004
Posts: 2,602
Likes: 88
From: Singapore
That sounds real great and exciting...on paper. Until you see the final product and realize how boring it is as they don't do much when they get hit by recall after recall (engine oil sluge recall anyone?).
But regardless of how boring it is any risk of drowsyness will be shocked wide awake when the gas paddle sticks and you realize the car ain't gonna hold up well in a crash. But don't worry, when the front end twists like a pretzel you still can escape from the trunk right. Then you realize they cut corner on the handle release. Now u really stuck.
But regardless of how boring it is any risk of drowsyness will be shocked wide awake when the gas paddle sticks and you realize the car ain't gonna hold up well in a crash.
But don't worry, when the front end twists like a pretzel you still can escape from the trunk right. Then you realize they cut corner on the handle release. Now u really stuck. Why is it boring? The 2GR-FSE engine in the IS350 and GS350 is as fast/faster than the equivalent twinturbo 3L inline 6 engine in the 335i and 535i in terms of 0-60 and 1/4 mile AND is proven to be more reliable to boot. And that's statistical and not just your anecdoctal evidence of engine sludge issues. Just read JD Powers, Consumer Reports etc about the overall statistical reliability of the 2GR-FSE.
Maybe the engine is boring to you because it doesn't have a plaque saying "Made by Break My Wallets?"
You do realize that several other German luxury models made around the same time as those Toyota/Lexus models(2005/6) had the same problems with the small overlap crash test. It was an industry-wide problem with only the Volvo models of that time performing well.
Talking about safety. Have you forgotten about the Infamous Elk test which showed how the 1st Gen Audi TT and MB A-class tended to turn turtle when performing evasive road manoeuvers? you forgotten Audi's horrendous safety scandal in the 80s?
Even the "unintended acceleration scandal" for Lexus has proven to be a bit of Media Fabrication as the original case involved the driver using the WRONG model's floormats for the car. AND subsequent complaints have never been substantiated aside from the very first case.
My point is this : It's a bit rich for you to highlight Toyota's/Lexus' supposed safety failures and contrasting it to the supposedly "perfect" German safety record when every manufacturer has had their share of safety issues. You seem to have an extremely selective memory when it comes to innovations and issues regarding Toyota and its German rivals. Perhaps you should see a neurologist.
Last edited by natnut; 12-27-12 at 02:27 AM.
12-27-12 | 03:28 AM
#12
That sounds real great and exciting...on paper. Until you see the final product and realize how boring it is as they don't do much when they get hit by recall after recall (engine oil sluge recall anyone?).
But regardless of how boring it is any risk of drowsyness will be shocked wide awake when the gas paddle sticks and you realize the car ain't gonna hold up well in a crash. But don't worry, when the front end twists like a pretzel you still can escape from the trunk right. Then you realize they cut corner on the handle release. Now u really stuck.
But regardless of how boring it is any risk of drowsyness will be shocked wide awake when the gas paddle sticks and you realize the car ain't gonna hold up well in a crash.
But don't worry, when the front end twists like a pretzel you still can escape from the trunk right. Then you realize they cut corner on the handle release. Now u really stuck.
12-27-12 | 07:17 AM
#13
Racer
Joined: Jan 2007
Posts: 1,936
Likes: 0
From: CA
No I am not the one with reading comprehension problem. I am simply calling out Toyota on their statement on how they save cost and time by cutting corner.
Toyota has been cutting corners for Decades long and it's coming back to bite them in the *** BIG time.
I am simply calling out Toyota on their statement on how they save cost and time by cutting corner. Toyota has been cutting corners for Decades long and it's coming back to bite them in the *** BIG time.
You seem to have a problem with reading comprehension. The dual injected GR-FSE as stated by me and several other posters has STELLAR reliability. Compare that to its contemporaries in BMW which came out around 2005/6 which had catastrophic problems with their turbo inline 6 engines.
Why is it boring? The 2GR-FSE engine in the IS350 and GS350 is as fast/faster than the equivalent twinturbo 3L inline 6 engine in the 335i and 535i in terms of 0-60 and 1/4 mile AND is proven to be more reliable to boot. And that's statistical and not just your anecdoctal evidence of engine sludge issues. Just read JD Powers, Consumer Reports etc about the overall statistical reliability of the 2GR-FSE.
Maybe the engine is boring to you because it doesn't have a plaque saying "Made by Break My Wallets?"
You do realize that several other German luxury models made around the same time as those Toyota/Lexus models(2005/6) had the same problems with the small overlap crash test. It was an industry-wide problem with only the Volvo models of that time performing well.
Talking about safety. Have you forgotten about the Infamous Elk test which showed how the 1st Gen Audi TT and MB A-class tended to turn turtle when performing evasive road manoeuvers? you forgotten Audi's horrendous safety scandal in the 80s?
Even the "unintended acceleration scandal" for Lexus has proven to be a bit of Media Fabrication as the original case involved the driver using the WRONG model's floormats for the car. AND subsequent complaints have never been substantiated aside from the very first case.
My point is this : It's a bit rich for you to highlight Toyota's/Lexus' supposed safety failures and contrasting it to the supposedly "perfect" German safety record when every manufacturer has had their share of safety issues. You seem to have an extremely selective memory when it comes to innovations and issues regarding Toyota and its German rivals. Perhaps you should see a neurologist.
Why is it boring? The 2GR-FSE engine in the IS350 and GS350 is as fast/faster than the equivalent twinturbo 3L inline 6 engine in the 335i and 535i in terms of 0-60 and 1/4 mile AND is proven to be more reliable to boot. And that's statistical and not just your anecdoctal evidence of engine sludge issues. Just read JD Powers, Consumer Reports etc about the overall statistical reliability of the 2GR-FSE.
Maybe the engine is boring to you because it doesn't have a plaque saying "Made by Break My Wallets?"
You do realize that several other German luxury models made around the same time as those Toyota/Lexus models(2005/6) had the same problems with the small overlap crash test. It was an industry-wide problem with only the Volvo models of that time performing well.
Talking about safety. Have you forgotten about the Infamous Elk test which showed how the 1st Gen Audi TT and MB A-class tended to turn turtle when performing evasive road manoeuvers? you forgotten Audi's horrendous safety scandal in the 80s?
Even the "unintended acceleration scandal" for Lexus has proven to be a bit of Media Fabrication as the original case involved the driver using the WRONG model's floormats for the car. AND subsequent complaints have never been substantiated aside from the very first case.
My point is this : It's a bit rich for you to highlight Toyota's/Lexus' supposed safety failures and contrasting it to the supposedly "perfect" German safety record when every manufacturer has had their share of safety issues. You seem to have an extremely selective memory when it comes to innovations and issues regarding Toyota and its German rivals. Perhaps you should see a neurologist.
Last edited by Stormwind; 12-27-12 at 07:22 AM.
12-27-12 | 07:19 AM
#14
Racer
Joined: Jan 2007
Posts: 1,936
Likes: 0
From: CA
No my German car has been in the shop for 3 years now and I take the bus home. They stop giving me loaners after 2 years. Hey the guys on the bus are always impressed when I told them how wonderful my german car drive and handles.
Hey the guys on the bus are always impressed when I told them how wonderful my german car drive and handles.
12-27-12 | 10:04 AM
#15
Pole Position
Joined: May 2004
Posts: 2,602
Likes: 88
From: Singapore
BMW looks like their *** is getting bitten big time too lol
Look. We can go back and forth on this issue endlessly but this is getting childish and just becoming a game of he said, she said (as well as boring to me.)
You've regurgitated your case ad nauseum several times now. Any more repetition will be bordering on the margins of trolldom.