Production control is introduced not merely to ensure that the goods will be produced on time, but is also meant to see that the goods produced are of the right quality. This is done through inspection of the products manufactured. Since the purpose of inspection is to compare the products with the standards of quality set earlier, it too, can be regarded as an effective agency of production control. One way of inspection is to examine the quality of finished products at the end of the process of production. But this may involve too much of wastage in the form of rejected products. To minimize the rejection of defective products, inspection may be conducted at every stage of production. Inspection can occur at three points: before production, during production, and after production. The logic of checking conformance before production is to make sure that inputs are acceptable. The logic of Continue reading
Operations Management
Analyzing Toyota’s Recipe for Success – The Toyota Way
The fundamental reason for Toyota’s success in the global marketplace lies in the so called “Toyota way”. The Toyota Way is not only about technology and efficiency, it is about doing the right thing for the company, its employees, the customer and the society as a whole. In other words, the incredible success of the Toyota way is a direct result of operational excellence. Toyota has turned operational excellence into a strategic weapon. This operational excellence is only in part based on tools and quality improvement methods made famous by Toyota in the manufacturing world, such as JIT, Kaizen, and one-piece-flow. Although such techniques helped spawn the “lean manufacturing” revolution, tools and techniques are no secret weapon for transforming a business. Toyota’s continued success at implementing this tools stems from a deeper business philosophy based on its understanding of people and human motivation. Its success is ultimately based on its Continue reading
Kaizen and Kanban in Lean Manufacturing
Kaizen Kaizen is broadly interpreted as the Japanese term for continuous improvement, although it is perhaps more accurately translated as a form of control. It applies to all aspects of organisational output, and can thus be linked to both Toyota Production System (TPS) and types of waste, as well as the means of introducing and managing basic employee working conditions. One of the most popular tools of Kaizen is a Kanban, which of itself translates to differing types of organisational process control, which collectively lead to greater organisational production efficiency. The overarching principle of Kaizen, and Kanban within that, is to create a ‘pull through’ organisational process, as opposed to push through. Historically, for many manufacturing organisations, understandably, they would place the manufacturing process itself at the heart of operations, and would strive to make this element as efficient as possible working towards metrics such as overall equipment Continue reading
Concept of Supplier Relationship Management (SRM)
An important feature of a world class organisation is the way the organisation has been able to develop and link its suppliers with its external processes. Supplier relationship management can be defined as the relationship that exists between the supplier and its buyer based on long term commitments and trust with the ultimate aim to maximize the potential value of the relationship. This will include the management of different forms of supply relationships such as partnership, joint venture and vertical integration. The critical importance of supplier relationship types to achieve supply chain competitiveness can be viewed under the following headings: The effective use of strategic partnership Typical traditional short term relationship is characterize by irregular or ‘one-off’ transactions that give rise to supply uncertainties, difficulties in choosing suppliers, and is price oriented making this type of relationship unreliable and unsupported. Organisations can move from this type of relationship towards a Continue reading
The Toyota Production System (TPS) – Meaning and Methods
A key success factor that enabled Toyota to become the world’s most successful automobile company is its famous manufacturing method, the so called Toyota Production System (TPS). The evolution of the Toyota production system approach can be traced to the period immediately following the second world war when the economic outlook was uncertain and human, natural and capital resources were in limited supply. Against this background, the most important objective of the Toyota System has been to increase production efficiency by consistently and thoroughly eliminating waste. This concept developed between 1948 and 1975 by Toyota’s former president Toyoda Kiichiro and later by Ohno Taiichi and Eiji Toyoda represents a highly efficient production system that is similar to that of Henry Ford several decades earlier, although Toyota’s approach to both product development and distribution proved to be much more consumer-friendly and market-driven. The main objective of TPS is to produce goods Continue reading
Efficiency of Material Handling Systems
The efficiency of material handling could be judged by the following principles: 1. “Equipment built for motion should be kept in motion; idle Equipment should be kept inexpensive”. 2.”Continuous material movement is most economical” This principle states that materials handling efficiency is Greatest when it approaches a steady flow of materials, in as straight as possible, with minimum interpretations and minimum backtracking and where movements approach continues rather than intermittent flow. It is not; always possible, in practice, to completely achieve the objective of this rule. However, it is the target towards which we Aim our thinking. Conveyors systems, both overhead and floor types, are excellent examples of the application of this idea. 3. “Materials’ handling economy is generally directly proportional to the size of load handled” We all recognize, however, that as the load size increases There is a point reached beyond which it becomes more costly, and less Continue reading