Quality Assurance Team

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Quality Assurance Team

• Nicolas Lee
• Mike Turbak
• Steven Seehusen
• Ryan Justen
• Brandon Asplund
• Fall 2004, University of Minnesota

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The Toyota Production System

• Unique production system
• Allows for continuous quality improvement
• Rated best vehicle in all categories for quality
  by JD Power
• GM, Chrysler, and Ford have tried to develop
  Toyota like production systems
• Scientific method is ingrained in Toyotas
  production process
• Teaches the scientific method to all levels of
  the organization

3
The Four Rules

• The four rules guide design, operation, and
  improvement for every product
• Rule 1 Scope shall be clearly defined
• Rule 2 Every customer-supplier connection must
  be direct and unambiguous
• Rule 3 The pathway for every product and service
  must be simple and direct
• Rule 4 All improvements must be made in
  accordance with the scientific method

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Rule 1

• All work shall be highly specified
• Scope is clearly defined
• Case study seat installation
• Bolts are always tightened in the same order
• Time taken to turn each bolt is specified
• Torque of each bolt is specific value

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Rule 2

• Every customer-supplier connection must be direct
• Case study seat installation
• Acquisition of seat bolt covers by installer
• Request is given to materials handler
• Request specifies part number, quantity of parts,
  location of part supplier, and location of the
  installer
• Coordinated materials handling prevents time lost
  in production

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Rule 3

• The pathway for every product and service must be
  simple and direct
• Case study seat installation
• Seat installer requests more plastic bolts covers
• No forks or loops in supply chain
• Installer materials handler designated
  supplier
• Goods flow from to specific person or machine

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Rule 4

• All process changes must be made in accordance
  with the scientific method
• Case study edging tape installers
• Initially not responsible for solving problems
• Assigned a leader to train them formulate and
  test hypotheses
• Using the scientific method they reduced defect
  rates by 90

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Toyotas Ideal Production System

• The output of an ideal person or machine is
• Defect free
• Can be delivered one request at a time
• Can be supplied on demand in the version
  requested
• Can be delivered immediately
• Can be produced without wasting labor, energy, or
  other resources

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Summary of Quality Control

• Define Define the problem/opportunity, process,
  and customer requirements
• Measure Define measures, collect, compile, and
  display data
• Analyze Scrutinize process details to find
  improvement opportunities
• Improve Generate solutions and ideas for
  improving the problem
• Control Track and verify the stability of the
  improvements and the predictability of the
  solution

www.kathyschwalbe.com
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References

• Spear, Steven and H.Kent Bowen Decoding the DNA
  of the Toyota Production System." Harvard
  Business Review Sept-Oct 1999. 97-106.
• Best Initial Quality by JD Power." JD Power and
  Associates. 2004. http//www.jdpower.com/cc/auto/r
  eleases/search.asp?CatID1
• http//www.toyota.com