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Toyota Tps Model

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Question: Where does the current routine for handling defective seats deviate from the principles of the Toyota Production System? Identify at least three deviations from the TPS Model associated with the problem prevention solving method?
During seat installation, it was discovered that defected seats were being delivered by KFS Manufacturing. This resulted in a high level of cars being pulled from the assembly line and sent to an offline repair area, also known as “the repair clinic”. As the cars accumulated in the repair clinic, TMM began to address the problem as follows: First, a team member pulled the andon cord to report the problem to the team leader before installing the defective seat. As this point, the team leader pulled the andon cord to signal “ok” and to tag the cars to alert Q.C. members about the defective seat problem. The car then went through the regular assembly line as usual with the defective seat installed. This is where the first deviation from the TPS model began. In the TPS model, repair of the seat would have been attempted on the line. This did not happen. Instead, the problem started to manifest into many problems, the failure of not adhearing to andon created“Never produce a defect – never pass a defect on” occurred when the cars were allowed to continue through the assembly line
According to the TPS model, problems are solved in space & time as close as possible to where the problem occurred. In the TPS Model, an attempt to resolve the problem should have taken place right there at the seat installation station. When it became apparent that the seats were defective, the second deviation occurred. In the TPS Model a shutdown of the line should have taken place. This did not happen because the final assembly operators felt that stopping the line would be far too expensive. Not taking the time thinking about how to…...

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