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To address the seat problem we would focus on finding out why there are so many defects in seat installation and production Is it because of the supplier of the part Or are the problems due to Toyota Doug should also determine whether the process of installing and manufacturing the seats is allowing Toyota to efficiently identify the cause of problems and breakdownsAs the Toyota plant Manager we would focus our attention on the following areasa We will investigate the engineering change from metal to plastic Although the hook breakage frequency went down in April the process should be monitored further to determine if it contributes to the frequency of defects in the seat installation stationb Doug should work with the supplier Kentucky Framed Seat KFS to reduce supplier defects and errors Because the frequency of defects has increased TMC is often forced to hold more cars in finished goods inventory There should be a concerted effort to improve the readiness of KFS in the change over process This can be done by further reengineering of the KFS plant to make them more efficient in dealing with the changeover to a new model over a very short period In addition TMC alongside KFS should institute a worker training program for the new models To further reduce the defects from KFS TMC should work with its planning department to give KFS more lead-time in preparing their plant for the new modelsc Because the seat defects are a problem in the line we recommend TMC build a safety inventory of seats By doing this the cars will not be pushed through the line Having a safety inventory of seats will make it more realistic for the plant to implement a Kanaban systemd Doug should determine if the plant can distinguish between defects from TMC and KFS If this is possible the TMC should institute a work in process inventory cap WIP or Kanaban system on the
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