Toyota TPS - Industrial Engineering Activities and Jobs

Information for IE - Case 59 - Industrial Engineering ONLINE Course.

The success of Toyota in cost reduction, productivity improvement, and international competitiveness and its celebrated Toyota Production System, fulfilled the dream of Yoichi Ueno (that Japan can guide US in improved practices of efficiency improvement). The success of #Toyota and the World Class #TPS was  built on the sustained efforts many Japanese persons who understood Taylor and Gilbreth's writings and improvised them in implementing them in Japanese companies.

http://nraoiekc.blogspot.com/2016/06/yoichi-ueno-japanese-leader-in.html

Toyota production system (TPS) evolved out of Toyota-style Industrial Engineering.

The two eminent persons directly involved in development of TPS - Taiichi Ohno and Shigeo Shingo made this statement in their books. Taiichi Ohno first authored a book on TPS for disseminating the concept and practices of TPS to other companies in Japan. Then using that book as the source material and foundation, Shigeo Shingo explained the role of industrial engineering in the development of TPS. Industrial engineers have to read Shingo's book to understand the important role industrial engineering philosophy and methods played in the emergence of work class manufacturing system of that period. Read about birth of TPS in an interview of Taiichi Ohno - How it all began - Taiichi Ohno.

Toyota uses all four. It is a pioneer in JIT.  Workplace organization includes Jidoka and JIT. Jidoka is concerned with developing excellent machine - man system. JIT is concerned with eliminating the waste or cost of work-in-progress or process (WIP) inventories.

Industrial Engineering - Productivity Improvement - Process Improvement - Product Redesign - Continuous Improvement

Industrial engineering is improvement in various elements of engineering operations to increase productivity. Along with engineering elements, industrial engineers evaluate and improve many other elements also as they are responsible for productivity and cost of items produced in a process. Through assignments of improving productivity and efficiency of information technology and software engineering processes, industrial engineers specializing in IT were given responsibility for business processes also. Thus industrial engineers with focus on various branches of engineering provide their services to companies and society to improve various elements of the products and processes on a continuous basis over the product life cycle. They are active in engineering or production-maintenance-service-logistic processes and business processes.

Productivity improvement always focuses on quality and flexibility issues as productivity improvement should not lead to any deterioration in quality or flexibility. Delivery and cost are always at the core of industrial engineering. Thus when QFCD paradigm came, that is attention to quality, flexibility, cost and delivery became prominent, many industrial engineers were given the responsibility of managing this function of continuous improvement.

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Focus Areas of Industrial Engineering - Brief Explanation

Productivity Science: Science developed for each element of machine operation and each element of human tasks in industry.
Productivity Science - Determinants of Productivity

Product Industrial Engineering: Redesign of products to reduce cost and increase value keeping the quality intact.
Product Industrial Engineering

Process Industrial Engineering: Redesign of processes to reduce cost and increase value keeping the quality intact.
Process Industrial Engineering

Industrial Engineering Optimization: Optimizing industrial engineering solutions created in Product Industrial Engineering and Process Industrial Engineering.
Operations Research - An Efficiency Improvement Tool for Industrial Engineers

Industrial Engineering Statistics: Using statistical tools like data description, sampling and design of experiments in industrial engineering activity.
Statistics and Industrial Engineering

Industrial Engineering Economics: Economic analysis of industrial engineering projects.
Engineering Economics is an Efficiency Improvement Tool for Industrial Engineers

Human Effort Industrial Engineering: Redesign of products and processes to increase satisfaction and reduce discomfort and other negative consequence to operators.
Motion Study - Human Effort Industrial Engineering

Productivity Measurement: Various measurements done by industrial engineers in industrial setting to collect data, analyze data and use the insights in redesign: Product Industrial Engineering and Process Industrial Engineering.
Industrial Engineering Data and Measurements

Productivity Management: Management undertaken by industrial engineers to implement Product Industrial Engineering and Process Industrial Engineering. Management processes industrial engineering is also part of productivity management.
Productivity Management

Applied Industrial Engineering: Application of industrial engineering in new technologies, existing technologies, engineering business and industrial processes and other areas.

Applied Industrial Engineering - Process Steps

How many Industrial Engineers can a Company Employ for Cost Reduction?

For $100 million cost, there can be one MS IE and 6 BSIEs.
https://nraoiekc.blogspot.com/2020/03/value-creation-model-for-industrial.html

Industrial Engineering - Lean Manufacturing - Parent - Child Relationship

Toyota Motors - Industrial Engineering Activities and Jobs

Toyota Motors is the pioneer in JIT. Just in Time production that eliminates long term storage and short term delays in flow.

Toyota Motors enriched industrial engineering immensely. ASME standardized the process flow chart with two categories focusing on temporary delays on the shop floor and storage in stores or warehouses. It is the Toyota executives who reasoned that these two stages are costing money, but not adding any special value to the transformation of input materials into required product. They focused on this aspect to develop a flow production system that does not require inventory in the store or on the shop floor. Their quest led them to make improvements in the basic transformation operation/process, inspection operation, and material handling/transport operation. The improvements made to these three steps in process flow chart gave a competitive edge to Japanese production systems and they are appreciated with the term "World Class Manufacturing."

Toyota reports its cost improvement activities in its annual reports and investor presentations. Shigeo Shingo explained the role of industrial engineering in Toyota Motors and Toyota Production System in a book.

Industrial engineering is profit engineering - Taiichi Ohno

Development of Toyota’s unique IE-based kaizen method (T. Ohno, Toyota Production System, p. 71):

“IE [industrial engineering] is a system and the Toyota production system may be regarded as Toyota-style IE… Unless IE results in cost reductions and profit increases, I think it is meaningless.”
https://bobemiliani.com/toyotas-secret/

2018-19 Annual Report Presentation
TPS/Cost Reduction
Cost Reduction Efforts:  +80
Decrease in Expenses:   -165

Details:
Labor Costs -45.0
Depreciation -20.0
R&D Expenses +15.0
Other Expenses, etc. -115.0


Latest article on TPS

Ishigame K. (2020) Enhancing Learning Through Continuous Improvement: Case Studies of the Toyota Production System in the Automotive Industry in South Africa. In: Hosono A., Page J., Shimada G. (eds) Workers, Managers, Productivity. Palgrave Macmillan, Singapore
https://link.springer.com/chapter/10.1007/978-981-15-0364-1_9

Steps in Assistance to Suppliers
[1st Stage: 5S and Understanding Current Conditions]
1. Understanding material and information flows - Transport, delays and storage in Process flow chart.
Understanding production systems - Operations of machines, men and maintenance of machines
Finding problems and outstanding issues
2. Thorough 5S
3. First in, first out (FIFO)


[2nd Stage: Making Production Management Tool]
1. Prepare operation standards

• Operation manuals  - Process - Machine operation, man operation
• Quality check standards - Inspection operation
• Machine maintenance manuals 

2. Prepare abnormality management tools

• Operator placement map - Record abnormalities - Improve
• Production performance board - Record abnormalities - Improve
• Defect parts control  - Record abnormalities - Improve

3.Prepare key performance indicators (KPI)


[3rd Stage: Kaizen Activity]
Focus on improving

1. One-piece flow, SEIRYUKA (rectification of production flow)
2. Pull system, Fill-up system (Kanban system)
3. Heijunka production
4. Standardized work - Improvement of operations included in operation manual
5. Motion Kaizen, multi-skilled operator - Improvement in man's operations

Taiichi Ohno on Industrial Engineering - Toyota Style Industrial Engineering

https://nraoiekc.blogspot.com/2013/11/taiichi-ohno-on-industrial-engineering.html

A Study of the Toyota Production System from an Industrial Engineering Viewpoint - Shigeo Shingo

https://nraoiekc.blogspot.com/2012/04/study-of-toyota-production-system-from.html

Shigeo Shingo - Toyota Production System (TPS) - Industrial Engineering Principles and Practices

https://nraoiekc.blogspot.com/2020/03/shigeo-shingo-toyota-production-system.html

Toyota Production System - Use of  Industrial Engineering Principles and Methods - Shigeo Shingo

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Toyota’s new $80 million engineering center in Kentucky
BY TOM EBLEN
OCTOBER 30, 2017
Lexington Herald-Leader
100 Midland Avenue
Lexington, KY 40508-1999
https://www.kentucky.com/news/business/article181684231.html

Toyota -  Industrial Engineers

Petro Nkosi
Industrial Engineer at Toyota South Africa
Johannesburg Area, South Africa
https://www.linkedin.com/in/petronkosi/

Mohale Mashatola
Senior industrial engineer at Toyota motor manufacuring South Africa
Durban Area, South Africa
https://www.linkedin.com/in/mohale-mashatola-ba4282bb/

Thifhelimbil Victor
Junior industrial Engineer at Toyota South Africa
Johannesburg Area, South Africa
https://www.linkedin.com/in/thifhelimbil-victor-53a741130/

NJABULO MADONDO
Industrial engineer at Toyota SA Motors
Durban Area, South Africa
https://www.linkedin.com/in/njabulo-madondo-12845b3a/

Lucky Velile Mhlongo
Industrial Engineer at Toyota Motor Manufacturing South Africa
Johannesburg Area, South Africa
https://www.linkedin.com/in/lucky-velile-mhlongo-18418b82/

Salisha Naidoo
Industrial Engineer, Business Process Analyst at Toyota Industrial Equipment
Johannesburg Area, South Africa

Mariz Bicongco
Industrial Engineer at Toyota Motor Philippines Corporation
Laguna, Calabarzon, Philippines
https://www.linkedin.com/in/marizbicongco/

Akpo A.
Industrial Engineer at Toyota Motor North America
Plano, Texas
https://www.linkedin.com/in/akpo-a-2946477/

Janelle Bedessy
Human Resources Business Partner at Toyota South Africa (Industrial Engineering and Post Grad BA Degree)
Durban Area, South Africa
https://www.linkedin.com/in/janelle-bedessy-4b904431/

Kwanele Buthelezi
Industrial Engineer at Toyota SA
Durban Area, South Africa
https://www.linkedin.com/in/kwanele-buthelezi-a1584615b/

João Ferreira
Toyota Caetano Portugal, S.A.
Company Name: Toyota Caetano Portugal, S.A
Industrial Engineer
Porto Area, Portugal

https://www.linkedin.com/in/jo%C3%A3o-ferreira-67b3664b/


09/02/2009 08:58

Author 3744  Ronald Turkett

Fujio Cho, Toyota's Chairman, noted that TPS was applied industrial engineering and common sense. For many years I have thought about his comments at the Georgetown, KY site and it still makes sense today. As an adjunct faculty member at the U of Michigan department of IOE I taught TPS in a class called Manufacturing Strategies.
https://www.lean.org/FuseTalk/forum/messageview.cfm?catid=44&threadid=4592

Ronald Turkett is a MSIE.

LEAN MANUFACTURING IMPLEMENTATION  Presentation

Ronald Turkett

1999

https://present5.com/lean-manufacturing-implementation-lean-supply-chain-university-of/

Toyota Industrial Engineering Job Advertisements

Industrial Engineer

Toyota Bacoor Cavite, Inc.

Cavite

Posted August 14, 2020

https://ph.joblum.com/job/industrial-engineer/267128

Job Description

The Job Controller’s / Industrial Engineer's general responsibility is to assist the foreman in the job loading and monitoring of technicians.

Functional Description of Position Responsibility:

Assist the foreman in updating and monitoring of the job with the use of the Job Progress Control Board,

Under a computerized set-up, the Job Coordinator also functions as the data encoder on the computer,

Updates the Daily Work Control Sheet, where the units received are logged and,

Accomplishes reports related to workshop operations

Determine daily available manpower capacity based on the total hours of the available Technicians

Record all repair orders onto dispatch log and determine the repair time required.

Distribute repair orders to the most appropriately skilled technician based on priority and completion time

Distribute repair orders with expected job completion time

Monitor and follow-up on work progress for each technician to insure completion on time

Indicate and record the incidences and cause of job stoppages

Record number of and causes of repeat repairs

Record number of and causes of carry overs

Prioritize waiting customers, repeat repairs and carry over work

Keep Service Advisors inform when no more work can be taken base on available hours.

Maintain accurate time keeping records by ensuring all technicians clock on and off all repair orders and day cards

Keep Service Advisors informed of job delays and any additional work required

Control the distribution of all sublet repairs

Coordinate with the parts department in preparing parts for the next repair orders to be worked

Efficient distribution of all repair orders

Authorized to dispute and monitor all repair work to the Technicians

Works in cooperation with the Foreman and Service Advisors to ensure full utilization of department capacity

Minimum Qualifications

Candidate must be a graduate of Industrial Engineering

 

Hiring Company

Toyota Bacoor Cavite, Inc.

Toyota Bacoor Cavite, Inc. was established on January 21, 2015 as a franchised dealer of automobile products and services distributed by Toyota Motor Philippines Corporation. 

https://ph.joblum.com/job/industrial-engineer/267128

Toyota Motor Manufacturing Canada

https://toyotamotorjobs.tmmc.ca/x/detail/a28fe4i9innl  (Accepting applications on 14 December 2020)

Engineering Analyst

Summary

Title: Engineering Analyst

ID: 1029B

Employment Group: Engineering

Location: Cambridge and Woodstock, ON

Toyota Motor Manufacturing Canada is committed to providing accommodations for applicants with disabilities; please advise us if you require an accommodation during the recruitment process.

Description

Toyota Motor Manufacturing Canada (TMMC) is a world-class automotive facility with manufacturing plants located in Cambridge and Woodstock, Ontario. Our plants currently manufacture the best-selling Toyota RAV4, RAV4 Hybrid and the Lexus RX 350 and RX 450h vehicles, and will also soon be building the popular Lexus NX and Lexus NX Hybrid models. Recognized year after year on the global stage for manufacturing quality by our customers, we are also recognized as one of Canada’s Top 100 Employers.

The world famous Toyota Production System, a philosophy of continuous improvement and on-going training, enables each Team Member to work towards their highest potential. The success of our company stems from hiring results-driven, self-motivated individuals, with the ability to work together to achieve team goals.

To promote a comfortable, safe and productive work environment, as well as to comply with all federal, provincial and/or local laws, TMMC is a smoke free property.

What we Offer:

Competitive salary, shift premiums and over-time pay rates, on top of base rate.

Exceptional Total Rewards Package

Training, development, and growth opportunities

Tuition Reimbursement Program

Free onsite fitness facility

Employee and family vehicle discounts

Social and team sport events 

Full service cafeterias including Tim Horton’s and Panago

 

Positions Available:

We are looking for Junior, Intermediate and Senior level Engineers candidates for multiple Engineering openings within various shops in our plants: Weld, Press, Assembly, and Paint/Plastics.

Overview of Engineering at TMMC:

Application of the Toyota Production System (TPS) to resolve production issues and help production achieve KPIs

Hands-on problem solving and critical thinking

Provide Technical Leadership for Project Management & Implementation

Use of engineering tools for Root Cause Analysis

Focus on Continuous Improvement

Work and collaborate with cross functional groups (quality, production, maintenance, contractors, suppliers, and management) 

 

Responsibilities:

Lead and perform root cause analysis on production, engineering, equipment and maintenance issues

Lead daily troubleshooting activities, provide solutions and support for process concerns or improvement

Coordinate and implement quality control objectives, activities and procedures to resolve production problems, maximize reliability and minimize costs

Perform Kaizen projects to improve safety, quality, productivity, efficiency and cost

Automation troubleshooting, new equipment installation and modifications

Process equipment evaluation, specifications, procurement and implementation

Ensure equipment and systems comply with relevant standards and legislation to ensure equipment safety and compliance

Co-ordination of external skilled trades / supplier /activities

Budget setting, forecasting and control

 

Desired Skills and Experience:

Engineering Degree. Mechanical, Manufacturing, Mechatronics, Electrical, Industrial backgrounds considered, P. Eng eligible

Minimum of 1 - 3 years of experience (co-op experience considered)

High volume manufacturing environment

Multi-disciplinary experience in process or equipment engineering

Experience in assembly plant manufacturing (automotive preferred)

Emphasis on manufacturing process and equipment

Automation experience is an asset

Knowledge and experience in the application of SPC (Statistical Process Control)

Technical experience/knowledge of torque control, production line control systems

Strong data analysis experience required

Must be proficient with MS Office, AutoCAD, 3D imaging software – SolidWorks or CATIA preferred and SAP is an asset

Excellent verbal and written communication skills

Strong leadership and technical skills

 

TMMC is an equal opportunity employer committed to building a diverse workforce. We believe in enabling people of different ages, sexes, sexual orientations, gender identities, gender expressions, colours, races, ancestries, citizenships, ethnic origins, places of origin, and creeds to work together and realize their full potential. TMMC is committed to compliance with all applicable legislation including providing accommodation for applicants with disabilities. Please advise us at any point during the recruitment and selection process if you require accommodation.

Updated on 29.7.2023,  27 August 2021, 29 July 2021,  14.12.2020,  15 July 2020
23 April 2020