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Stephen Gann

MKT 522, Toyota Case

1 As Doug Friesen, what would you do to address the seat problem? Where would you
focus your attention and solution efforts?
The seats defects starts with the KFS manufacturing. KFS is producing
products with material flaws and missing parts that could originate during
production or while in shipping. First, Doug should visit the site of production of
the seats as well as meet with the quality control team at KFS. Second, if the
quality team and production seems up to par, I would look into the packaging,
shipping, and transportation of the seats in order to find any flaws. If flaws in
either manufacturing or shipping are not addressed and fixed I would look to
other manufactures for the seats.
I would focus on uncover the problems at KFS. Once the problems are
fixed with KFS, I would focus on TMM. I would try and reduce off-line required
assemblies as well as production stoppage. If the problems at KFS are addressed
properly in theory there should be less problems down the productions line with
TMM.
2 What options exist? What would you recommend? Why?
The best option would be to simplify the seats or decrease the variety of
seats manufactured. As unhappy as the designers will be, this option will simplify
he production and installation processes. Simplicity is a key in efficiency.
Another option would be to train the installers on how to install faster, and with

more care towards the product to reduce broken parts. The last option would be to
replace KFS with another manufacture.
I would recommend simplifying the seats and cutting the variety of seats
offered out. Simplifying dose not mean lower quality, in fact simplifying could
lower cost, which could be reintroduced in higher quality materials used. Training
is expensive and only necessary if simplification of the seats dose not work. The
last option I would do would be to find another manufacture. It is easier to fix the
issues than to start all over again. This option is only used as a last resort.
3 Where, if at all, does the current routine for handling defective seats deviate from the
principles of the Toyota Production System?
By stopping production or moving he defected seated the cars off-line production,
Toyota is backing up the production process. The defected seats can be fixed
while other installations are going on. If stead of stopping or moving to off-line
Toyota should have a team that comes in to fix malfunctioning installation of
seats while the cars continues down the assembly. For example, you can fix the
seats while the car is having the headlights installed.
4 What is the real problem facing Doug Friesen?
The problem Doug is facing is the quality of the products being shipped to him. These
defected products are hindering his production line and reducing the run ratio from 95%
to 85%. 85% ratio means there are 45 cars less than average production per shift, which is
requiring overtime to fill the orders. The ratio is directly related to the malfunctioning
and broken products