Toyota Production SystemLean Production |
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In 2006 we converted our production operation into a “lean production facility," a single piece flow process based on the Toyota Production System. In 2009, we began to teach this methodology to others in order to continue with our own education as well as to better our industry. | |
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Lean involves keeping the product (vehicle) busy, not the people. |
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| By completing each step in the process error free, an uninterrupted “flow” is maintained. | ||
Below we show the transformation process and the current state. Because this system is based on continuous improvement, this can only be a snap shot of an ongoing journey
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| In the lean process, this “flow” is configured as a “pull system” wherein work is delivered when required by the customer and then sequentially back up-stream through the entire process. | ||
"Lean production is not just a collection of good tools like 'repair blueprinting' or 'team work'. It is a major cultural change that demands all the commitment and energy an organization has in order to be successful." |
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Great rewards are to be had in employee, vendor, and customer satisfaction. However, there can be significant barriers to its implementation in the collision repair industry. The biggest problem is the intellectual capacity of and behavioral change required of management. Many in our industry do not understand the true nature of this transformation. Trying “lean” a little at a time is not a good option and will result in lots of stress and possible failure. That being said, our industry has some very hard working and creative people at many levels and they will make this work when they put their mind to it.
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| If you feel you fit the profile and would like to speak with us further, we recommend that you explore some of these resources first: | ||
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Remember, “lean is not a proprietary or patented system, it’s a never ending process of continuous improvement that involves major cultural change.” Good Luck! |
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