Mobilising Lean Manufacturing in the Automotive Industry with the Toyota Production System (TPS)

Lean manufacturing is a philosophy that emphasises reducing waste and streamlining processes to improve efficiency.

The automotive industry has been using lean techniques for decades, but how can electric tow tugs help manufacturers accelerate their production efficiency?

This article will explore:

• An overview of the Toyota Production System (TPS)
• Key wastes within lean manufacturing
• The challenges of implementing lean production
• How electric tugs support lean manufacturing
• The benefits of automation in automotive manufacturing

Just-In-Time (JIT) manufacturing

Making only “what is needed, when it is needed, and in the amount needed” – Toyota

Just-In-Time (JIT) manufacturing is an approach to designing, scheduling, and managing manufacturing processes that minimise inventory levels while maximising production efficiency. By employing a just-in-time inventory management system, manufacturers can reduce costs by eliminating unnecessary inventory and optimising their production processes.

Jidoka

Automation with human intelligence

Jidoka is a principle that focuses on problem solving and continuous improvement by empowering employees to quickly identify problems and take action to eliminate them. This is designed to prevent defective products from being produced – reducing waste.

What is Kaizen?

Kaizen is another key component of lean manufacturing principles that focuses on improving quality and efficiency through continuous improvement.

It aims to eliminate waste by creating a culture focused on identifying where improvements can be made, and then taking action to make those improvements.

Kaizen has been used successfully in the automotive industry to reduce lead times, increase productivity and decrease costs.

The challenges of implementing lean manufacturing

Implementing a lean manufacturing system is a continuous process that needs to be embedded within the company culture to succeed.

Some of the key challenges automotive manufacturers face when implementing lean manufacturing principles include gaining employee buy-in, dealing with resistance, managing change, measuring progress and ensuring quality standards are met.

A core challenge faced by automotive manufacturers we work with is balancing safety needs with productivity goals.

How electric tow tugs help manufacturers balance safety and efficiency

Reducing waste is core to lean thinking and as manufacturers seek to reduce wastes such as waiting, movement and underutilised workers, they are increasingly looking towards more efficient material handling solutions to support them.

Electric tugs are a battery-powered material handling solution designed to take the strain when moving heavy wheeled loads such as kitting trolleys, moulds, body-in-white (BiW) and parts.

Here’s two examples of how electric tow tugs help automotive OEMs reduce waste: