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TPS Benchmarking

Japan Kaikaku Experience Field Report, January 2007

Avatar photo By Jon Miller Updated on August 22nd, 2023

Recap of Our Recent Japan Kaikaku Experience-By Brad Schmidt

Toyota’s Innovation:

Toyota showcased an impressive update. They’ve introduced full kitting on specific sections of their assembly line. Kit carts follow the car down the line, returning empty for restocking. As a result, only bins of bolts and nuts remain on the line. This was a fresh approach they started in January 2007.

Toto’s Unique Production Line:

We visited “Toto’s toilet tank production”. Surprisingly, the factory featured traditional Japanese decor, even incorporating straw around chemical tanks for a homely touch. Despite having another factory in Shanghai, Toto’s production costs in Japan remain lower. An engaging Q&A session with the plant manager spanned about 1.5 hours. The standout at Toto was their vibrant “free and fun” spirit. Balancing this atmosphere while aiming for cost-cutting, especially in staffing, is a challenge they acknowledged.

Reflective Discussions:

Post visits, we engaged in discussions focusing on:

  1.  Our observations and likes
  2.  The rationale behind what we observed
  3. Potential applications of these insights to our businesses.

I’m thrilled to note that many participants experienced their kaikaku (mental breakthroughs) from Day 1 itself.

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  1. Erick Mortera

    January 28, 2007 - 5:30 pm
    Reply

    Full kitting is called Set Parts Supply System or SPS. It has been implemented in Tsutsumi plant since 2003. It is now widely practiced in other Toyota affiliates, such as Toyota Taiwan (Kuozui), Thailand (Gateway), India (TKM) and the Philippines (TMP). The main benefits are reduction of parts stock space and cycle time at line side. It results to steep learning curve and tremendous improvement in quality.

  2. Jon Miller

    January 28, 2007 - 6:07 pm
    Reply

    What Brad is describing is different than SPS at Tsutsumi. In the full kitting prior to this year, the kits were still kept on the line. What we saw at Motomachi on our last visit, all the kits were kept off the line and the kit travels with the car on a cart following a magnetic strip. I don’t know what this new synchronized method is called.

  3. Erick Mortera

    January 29, 2007 - 12:23 pm
    Reply

    Yes, SPS has three variations: SPS for man (single process), for vehicle (station process) and for the whole line (e.g the whole trimline assy) . What you saw is SPS for the whole line. It is the same with Toyota India and Philippines.

  4. Jon Miller

    January 29, 2007 - 4:50 pm
    Reply

    Thanks for sharing that insight Erick. I’ve learned something new.

  5. santosh

    March 8, 2010 - 9:31 am
    Reply

    what is milkrun method?

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