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introduction

Before beginning the book summary I would say that after having read

I think a book that any student about to graduate in Industrial Engineering is must

read. It is a book where you can see many of the concepts that are in various classes as

Organizational Process Improvement, System Design , Plant Planning , Design

Work, Technology Management and Project Management . But all seen a

holistically , from a systemic perspective noted a relationship between all

concepts and how they interact within a company , unlike classes where

the semester and then look back to see them or if not perhaps in another class take them as

reference but without getting very thoroughly and relate new learning. For that reason

I think it is very useful to read this book if you want to have a better grasp of those concepts

in the future be able to apply them in the workplace .

Coming now to the subject of the book itself , it was written by Dr. Jeffrey Liker who was in

program by the Japan Technology Management at the University of Michigan and

through there observed the differences between American and Japanese industry ,

mainly for Toyota ; for the realization of the book were interviewed several

Toyota workers from management to production people . The book is divided into three

sections: The first is called "The power of world-class Toyota Way " , the second " The

business principles of the Toyota Way "and the last " Applying Toyota Wat to your

body

chapter 1

In this first section of Toyota some statistics which highlights that their profit margin is 8.3 larger than the average are exposed to the automotive industry , the Lexus has been selling more units per year than BMW , Cadillac or Mercedes

Benz in the U.S., Toyota's development process quicker product in the industry with an average of 12 months while competitors take 2 to 3 years. Thus, in studies of benchmarking is known for its high quality, productivity, manufacturing speed and flexibility.

It is mentioned that the key to the success of Toyota 's operational excellence and that

is your strategic weapon which is based on principles such as JIT , Kaizen , One- piece Flow, and JidokaHeijunka . This creates the whole concept of Lean Manufacturing.

Moreover, the introduction is given to the TPS ( Toyota Production System) which differs

of the " Scientific Management " Taylor in the Western system that takes into account

a set of principles as: You better stop a machine to stop producing and not create

over- inventory, it is not necessary to keep workers busy all the time

manufacturing because it is better to follow customer demand , People is the most flexible resource

In the early years of the last decade Toyota has become the number one seller of automobiles in North America, beating GM , Ford and Chrisler . At the same time it has expanded and developed its product portfolio targeting markets luxury Lexus brand and creating efficient machines and friendly to the environment as the Prius.

Toyota invented lean production or "lean " , which in the book is referred to as "the Toyota Production System" (TPS ) and has generated a global transformation in virtually every industry .

Following the model of the 4P's of Toyota presents :

Troubleshooting

People and Partners

process

philosophy

When the Toyota methodology is applied correctly provide long-term benefits

organization , among which are:

• The elimination of resources and downtime

• Find low-cost alternatives to expensive technology

• Build a culture of learning in order to improve continuously

• Develop quality systems work

Business Principles of the Toyota Way

The principles are based the Toyota Way are divided into 4 groups:

Philosophy (Principle 1 )

Processes (Principles 2 to 8 )

Personal (Principles 9 to 11 )

Troubleshooting ( Principles 12 to 14 )

They must be seen as a pyramid because to move from one stage to another, you must

will dominate otherwise optimal performance will not be achieved . At first glance the

concepts may not apply to companies that produce specialized goods that are not mass production or service companies , however you have to understand the creative concepts to understand how to apply them , in fact mentioned in some chapters in isolation between applications companies service

chapter 2

The history of the Toyoda Family and the Toyota Production System

The story begins in the late Sakichi Toyoda IXX century and a weaving factory in Japan. Sakichi

was a born inventor who devoted his whole life to develop inventions that have a direct impact

positive in the society in which he lived. He was regarded as the "king of inventions " in Japan and among

his greatest achievements is tissue machine stopping automatically when

detected breaking a thread.

Sakichi Kiichiro sent his son to college to study mechanical engineering , so encouraging him

especially under the argument that " everyone should embark on a big project at least once in

his life. " Sakichi was sure Automatic sewing machines were technologies of the past and

it was part of their responsibility to raise their children to develop future technologies and

change the way people live .

chapter 3

eliminating waste

The waste removal process focuses on analyzing the parties in the production line

that generate customer value and those that do not generate . The purpose here is to reduce or eliminate the

possible all activities that do not create value for the customer .

Then the seven major classes of waste identified by Toyota is plus one

included by the author:

1. Overproduction

February . Timeout

Three . Unnecessary Transport

April . Processing or incorrect processing On

May . Excess inventory

6. Unnecessary movement

7. Defects

8. Employees Creativity unused

A tool used by Toyota for these analyzes is the generation of a time band showing the raw material from which it is introduced to the process until the finished products out . From these analyzes it is important to consider the time value is added onlysmall percentage of the total time . Likewise , the traditional view of cost reduction focuses only on the parts that add value . It should be mentioned that lean thinking focuses on the value stream to eliminate all activities that do not generate it .

The 5 techniques used to reduce waste are:

• Genchi Genbutsu

• The 5 Whys ?

• Eyes on waste

• Troubleshooting

Chapter 4

The culture behind TPS

This chapter briefly introduces the 14 principles of the Toyota management methodology.

Special emphasis on the importance to follow and understand each of these principles and the

Toyota method is one more than a number of techniques to follow philosophy.

Start with a practical example of the implementation of Kanban systems "pull" andons and visual signs, and as this is only the beginning of the process and lean methodology This is because although the entire plant could be seen as a Toyota plant the staff is not trained to operate the tools and even if they were not in keeping with the company philosophy and culture of continuous improvement. Each of the 14 principles will be discussed in later chapters.

chapter 5

The development of Lexus

This chapter talks about the experience that was for the development of the Toyota brand Lexus luxury car . The idea was born within the organization by Yukiyasu Togo , sales manager of the company in

U.S. . He himself recognized the niche market opportunity for Toyota and consumer need for an option that offers all the luxury brands like BMW, Mercedes- Benz and Audi could not offer .

The analysis began with a study of the market in which the reasons for purchase and rejection of competition for customers in the segment were studied. This analysis was performed by brand and by continent

they came from brands . After lists were generated for the priorities they had buyers for each of the brands and what they were thinking at the time of purchase.

After collecting the data the competitive advantages that would Lexus on specific models of the main competing brands were defined. These objectives are:

• Increased maximum speed

• Better fuel efficiency

• Low cabin noise

• Increased aerodynamics

• Low vehicle weight

Searched all Lexus cars are leaders in the segment without compromising properties, for example, wanted to generate a quick and fast car but with very low fuel consumption .

chapter 6

Prius

The development of the Prius is the clearest example of the tools and techniques of Toyota implemented. With the advent of the XXI Century Toyota executives recognized a potential problem in the middle of his new success in times like these is when complacency begins to hit managers from top companies lower their defenses and are exceeded in the market.

To reverse this Toyota focused on the generation of future car

...