Toyota Motor Manufacturing Case

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Toyota Motor Manufacturing, USA, Inc Case Analysis * Main and sub ideas of the case. The main topic of the case was the problems caused by defective or damaged seats. TMM USA's seat problem was threefold. The first was the actual defects with the hooks and the damaged caused by cross threading by employees when installing the seats. This problem led to the second problem, which was the departure from the Toyota Production System (TPS) when dealing with the seat problem. Rather than fix the problem with the seat when it happened, they continued with the car's production and worried about the seat afterwards. And this led to the third problem, a build up of cars with seat problems in the off-line operation area. In reading the case I…show more content…
Ø What options exist? What would you recommend? Why? There are about five different options that I believe Mr. Friesen could follow. The first is to adjust the seat assembly team. He should determine if there are any changes in employees, processes, or training that need to be made. The second option is to rework the off-line process. There needs to be something done to reduce the number of cars sitting on the overflow lot waiting for new seats. Possibly, a system that notifies employees when a car has been sitting in the overflow lot for more than four hours could be used. This should allow enough time for the correct seat to arrive and the problem fixed. Also, if the employee already knows that the seat needs to be reordered, why can't he reorder it right then. The third option is to redesign the seat to solve the problem of the breaking hook. Mr. Friesen did look into this and found that it would cost KFS $50,000 to redesign the seat. The question here would be how long would it take to recover the cost, is it not worth the cost to redesign it, or is there a better way to solve the hook breakage problem. Another possible solution to this would be to have the employee spend a little more time on installing the bolt through the hook and so will be able to use more caution. The next option is to look at KFS's production process. Why is it
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