I was a Quality Technician, a 5S/Lean-coordinator, and now I am a Supervisor at the same Company that has plant in, for example, Mexico too. And We supply Our products to Toyota. But these guys know something, that We all need to learn :)
Excuse my intervention, I'm a lean manufacturing consultant so I'd like to post a comment so the other people that see this video can understand little bit better about lean. 1.- Toyota also has plants and / or suppliers in Mexico, and the quality it's still great.
@SirishT Its alot more then that. You really have to look at where the parts come from to assemble those vehicles and were the profits go. Hyundai for example assembles a few cars in America but those cars US content are in the 30-40 percents. The most amount of auto manufacturing jobs comes from suppliers not from the actual assembly plant.
kaizen process would mean that an improvement was shown. There was no "before" and "after" footage shown. Don't quite know what you mean. This is just an overview of the plants within TMM Kentucky.
@seansdoesntdoweed There has been a study that in most cases the driver pushed gas instead of brake anyone who has driven a car knows that eventhough you are flatout and you push the brake the cars engine dies...
@videoslacker I just love Americans who like to take credit for all the good things in this world... Edward Deming was the developper of Quality Control Management. But building a car is more than quality control. And Kaizen is much more than that also. And let's not forget that E. Deming conducted his work in Japan, where he worked with Japanese, who later improved whatever he had initially developped... I don't like you implying that Japanese car manufacturers owe everything to E. Deming.
@Allante715 Ok. I was reffering to more general domains, not just car manufacturing, but as I know of, Subaru invented the electrical transmission, Honda invented the piston ring, valve lifts, timings, something the like (I'm not very good at mechanics, I'm sorry), Toyota invented the automatic looms, plus I might be wrong, but Nissan invented the first "plug-in-and-drive" system? :) And let's not talk about the corporate strategies which made everything possible. Just a few examples,that's all
@videoslacker He said they imposed a higher quality there; not the kind of "good enough" patted on a shoulder and move on like in Kentucky or Canada. That is why there are parts shortage, because quality doesn't mean quantity. And quantity often are cheap or risky or lawsuit or billions of dollar in damage for the company, priceless for the consumers. Trust and brand cost time and money or a lot more in money!
@390merc65 I heard they switch supplier and forgo quality inspection. Apparently, the supplier in Japan wanted a higher price and Toyota see them as not efficient as time consuming, costly, and other things so they switched to a closer supplier. But the standard is not the same and not consistent. The new supplier credibility is not as good as the old supplier. If you read theory M, there are that "clandestine" relation that Toyota forget : loyalty, good will, sacrifice, etc..
Not Ford though. Their quality has improved termendously over the years and they didn't need a bailout. Their quality has met Toyotas and Hondas in fact.
in other words, just to compensate for all of those benefits, the American car companies, have to inflate the price tag on their cars by and average of $3,000 USD per car. Not to mention that engineering, Human resources, quality, materials, and all of the other departments in their manufacturing plants HAVE to ask for permission to the Union to do the simplest thing,
What I find incredibly funny is that people don't realize that the so-called "superior" Japanese method of manufacturing is in fact American in origin. You people think I'm nuts? Look up a guy by the name of Edward Deming. The Japanese hold Deming's teachings in very high regard.
@cebokisha The sad thing is that Deming went to the big 3 first, and they basically laugh at him(I'm not kidding). So he took it to the Japanese and the rest is, as they say, history. Ford was about the only one that listened to Deming after that. GM and Chrysler...not so much.
3.-Unions----no commnents on that, ok, maybe one...toyota doesn't have them, or they are still manageable. while a GM union worker earns around $27 USD/hr or more as an average and if they work overtime and they could earn upto $70 USD/ hr.
@Allante715 That is false! It has been statistically proven that Japanese automakers create more inventions AND innovations than any other European or American country. Check "Strategic vs Evolutionary Management - A US vs Japan Comparison" book and you'll see what I mean.
@videoslacker You're comparing two completely different things here dude. Let's keep the argument to manufacturing in the 21st century at least so we are on the same playing field. Fact is Japanese work ethic (not accepting "good enough" attitude) shows in their product quality. Before you hit me with an emotional response go out and compare a Toyota vehicle made in Japan (Yaris, Prius, FJ, Scions) to those made in US (Camry, Tacoma, Tundra, etc) and you will see major differences in quality.
@videoslacker But it's Americans lack of discipline and poor leadership and management that makes Japaneses perfection of these "known" manufacturing methodologies unique and profitable. We blindly implement LEAN tools without understanding inherent characteristics that make them work in Japan.
Eh, Toyota should know the risks it undertaking for open a plant in such a place. I would at least study the area before open one. Did you watch rise of planet of the apes? definitely a worthwhile re-thinking of human behavior and emotion. Best place in the region would be Alabama. Best place in the region to sell cars would probably be Texas.
@cebokisha Did the Japanese invent the fuel injector? internal combustion engine? Headlights? Turn Signals? Adjustable Steering Column? Disk Brakes? Cruise Control? Electric Windows? Electric Ignition? Spark Plug? Muffler? Odometer? Seat Belts? ECT...ECT....ECT Give me an example of a Japanese invention or innovation that is on the majority of automobiles. Must be an original invention not an improvement. You can go tell me to read a book but the least you can do is give examples.
@mrzeolite Sir, I still label you a person that is basically saying that a nation of roughly 300 million are lazy. That is blatant generalization and racism no matter how you look at it(emotional or not). Are you saying that Americans cannot make good stuff at all? If that is the case, then I can name two hand built US made cars that truly are high-end machines; The Ford GT and the SSC Ultimate Aero(I call it the speed demon). Oh, and look up Nelson Racing Engines while you're at it.
I only say that most of the import is build in america. Premium models are build in japan. Its easy to see how many models are build in here, u can tell by the last recall. Looks like americans cant even follow up japanese instruction to produce and assemble the cars, that's really sad. All what americans can do is unionize !
@mrzeolite Sir, that what you just said automatically makes you racist in my mind. Some of the hardest working people I've ever meant and worked with were American. If the Japanese are suppose to be so freaking superior and disciplined, why did they call the US to help them fix their obsolete nuclear plants when that earthquake hit? I thought Japan was suppose to have a "superior" infrastructure. Sorry for getting pissed, but its about time someone lay the hammer down on this "hate the US" crap.
I was a Quality Technician, a 5S/Lean-coordinator, and now I am a Supervisor at the same Company that has plant in, for example, Mexico too. And We supply Our products to Toyota.
But these guys know something, that We all need to learn :)
I see...combining all of the pixels into one...eliminates waste! :)
Excuse my intervention, I'm a lean manufacturing consultant so I'd like to post a comment so the other people that see this video can understand little bit better about lean.
1.- Toyota also has plants and / or suppliers in Mexico, and the quality it's still great.
Great to see the inner workings of a Toyota plant.
2.- The TY way it's not a matter of nationality it's a matter of systems and making them work.
@SirishT
Its alot more then that. You really have to look at where the parts come from to assemble those vehicles and were the profits go. Hyundai for example assembles a few cars in America but those cars US content are in the 30-40 percents. The most amount of auto manufacturing jobs comes from suppliers not from the actual assembly plant.
kaizen process would mean that an improvement was shown. There was no "before" and "after" footage shown. Don't quite know what you mean. This is just an overview of the plants within TMM Kentucky.
'Hey make sure you put those sticky pedals in there good!" ahahaa
damn I love those bumper stickers DONT BUY IMPORT. but the IMPORT is made in here !
It looks like other auto assemble lines. I could not find lean concept applied in any part of this video. If you know, please share with me.
@seansdoesntdoweed There has been a study that in most cases the driver pushed gas instead of brake anyone who has driven a car knows that eventhough you are flatout and you push the brake the cars engine dies...
@videoslacker
I just love Americans who like to take credit for all the good things in this world...
Edward Deming was the developper of Quality Control Management. But building a car is more than quality control. And Kaizen is much more than that also. And let's not forget that E. Deming conducted his work in Japan, where he worked with Japanese, who later improved whatever he had initially developped... I don't like you implying that Japanese car manufacturers owe everything to E. Deming.
wondering whether there were any kaizen processes in this video?
@Allante715 Ok. I was reffering to more general domains, not just car manufacturing, but as I know of, Subaru invented the electrical transmission, Honda invented the piston ring, valve lifts, timings, something the like (I'm not very good at mechanics, I'm sorry), Toyota invented the automatic looms, plus I might be wrong, but Nissan invented the first "plug-in-and-drive" system? :) And let's not talk about the corporate strategies which made everything possible. Just a few examples,that's all
What do you mean almost. They ARE leading in the car manufacturing market.
@videoslacker
He said they imposed a higher quality there; not the kind of "good enough" patted on a shoulder and move on like in Kentucky or Canada. That is why there are parts shortage, because quality doesn't mean quantity. And quantity often are cheap or risky or lawsuit or billions of dollar in damage for the company, priceless for the consumers. Trust and brand cost time and money or a lot more in money!
Thanks for the info.
@390merc65
I heard they switch supplier and forgo quality inspection. Apparently, the supplier in Japan wanted a higher price and Toyota see them as not efficient as time consuming, costly, and other things so they switched to a closer supplier. But the standard is not the same and not consistent. The new supplier credibility is not as good as the old supplier. If you read theory M, there are that "clandestine" relation that Toyota forget : loyalty, good will, sacrifice, etc..
Not Ford though. Their quality has improved termendously over the years and they didn't need a bailout. Their quality has met Toyotas and Hondas in fact.
in other words, just to compensate for all of those benefits, the American car companies, have to inflate the price tag on their cars by and average of $3,000 USD per car. Not to mention that engineering, Human resources, quality, materials, and all of the other departments in their manufacturing plants HAVE to ask for permission to the Union to do the simplest thing,
What I find incredibly funny is that people don't realize that the so-called "superior" Japanese method of manufacturing is in fact American in origin. You people think I'm nuts? Look up a guy by the name of Edward Deming. The Japanese hold Deming's teachings in very high regard.
how many computers operate this plant
i'm an autobody painter and would like to know what size of needle tip does the robot use? What brand of paint?
where does toyota make lexus in the usa?
Great video, can we come for tours?
C-A-R-D-S!!!!
@cebokisha The sad thing is that Deming went to the big 3 first, and they basically laugh at him(I'm not kidding). So he took it to the Japanese and the rest is, as they say, history. Ford was about the only one that listened to Deming after that. GM and Chrysler...not so much.
@SirishT
You just keep thinking that.......
Where are the lean concepts? One of the main concepts that i know of is the concept of work cells, and this doesn't look to me like that.
@Allante715
Japanese invented Katana
3.-Unions----no commnents on that, ok, maybe one...toyota doesn't have them, or they are still manageable. while a GM union worker earns around $27 USD/hr or more as an average and if they work overtime and they could earn upto $70 USD/ hr.
@aznxdope are you chad nishida?
@videoslacker
Japanese automakers really never come up with original ideas. They just make a European or American design better.
@Allante715
That is false!
It has been statistically proven that Japanese automakers create more inventions AND innovations than any other European or American country. Check "Strategic vs Evolutionary Management - A US vs Japan Comparison" book and you'll see what I mean.
@videoslacker You're comparing two completely different things here dude. Let's keep the argument to manufacturing in the 21st century at least so we are on the same playing field. Fact is Japanese work ethic (not accepting "good enough" attitude) shows in their product quality. Before you hit me with an emotional response go out and compare a Toyota vehicle made in Japan (Yaris, Prius, FJ, Scions) to those made in US (Camry, Tacoma, Tundra, etc) and you will see major differences in quality.
@videoslacker But it's Americans lack of discipline and poor leadership and management that makes Japaneses perfection of these "known" manufacturing methodologies unique and profitable. We blindly implement LEAN tools without understanding inherent characteristics that make them work in Japan.
Eh, Toyota should know the risks it undertaking for open a plant in such a place. I would at least study the area before open one.
Did you watch rise of planet of the apes? definitely a worthwhile re-thinking of human behavior and emotion.
Best place in the region would be Alabama. Best place in the region to sell cars would probably be Texas.
they realized all american money is going to japan.
@Airsoftrisupetteri it was just a joke :p
@UnitedPebbles
Nevermind, I thought this video was for the Mississippi plant. Hahaha
Toyota will regret it.
They're americans not africans.
'
robotic make car / truck then must be cheaper to sell it,,,
NOT too much
TMMK likes METH
@cebokisha
Did the Japanese invent the fuel injector? internal combustion engine? Headlights? Turn Signals? Adjustable Steering Column? Disk Brakes? Cruise Control? Electric Windows? Electric Ignition? Spark Plug? Muffler? Odometer? Seat Belts? ECT...ECT....ECT
Give me an example of a Japanese invention or innovation that is on the majority of automobiles. Must be an original invention not an improvement. You can go tell me to read a book but the least you can do is give examples.
@mrzeolite Sir, I still label you a person that is basically saying that a nation of roughly 300 million are lazy. That is blatant generalization and racism no matter how you look at it(emotional or not). Are you saying that Americans cannot make good stuff at all? If that is the case, then I can name two hand built US made cars that truly are high-end machines; The Ford GT and the SSC Ultimate Aero(I call it the speed demon). Oh, and look up Nelson Racing Engines while you're at it.
I thought is KFC
See the big fat lean at :33 and 3:33. This is nothing new...
@aznxdope
Not a single reference to any tool used in Lean metodology nor any example of application. Bad video quality. Definitely 5 minutes wasted
I only say that most of the import is build in america. Premium models are build in japan. Its easy to see how many models are build in here, u can tell by the last recall. Looks like americans cant even follow up japanese instruction to produce and assemble the cars, that's really sad. All what americans can do is unionize !
@mrzeolite Sir, that what you just said automatically makes you racist in my mind. Some of the hardest working people I've ever meant and worked with were American. If the Japanese are suppose to be so freaking superior and disciplined, why did they call the US to help them fix their obsolete nuclear plants when that earthquake hit? I thought Japan was suppose to have a "superior" infrastructure. Sorry for getting pissed, but its about time someone lay the hammer down on this "hate the US" crap.
Quite many africans employed there!