Waste Elimination in Toyota
This work has been made complete by assistance from researched work on lean production. The written work gives ideas on how to eliminate waste. It highlights the basic way in which waste is eliminated in relation to Toyota Company. A brief introduction of Toyota Company is highlighted and then its detailed way of eliminating waste is discussed with justification. The researched work covers the ‘seven wastes’ plus two more.
Wastes (Muda) are products that are not used often and therefore thrown away because they do not add value in their old form to end products. Some wastes result in accidents hence the need to eliminate them from the environment. Other wastes on the other hand may make good final products when recycled like soda bottles. Almost everything in life ends up to waste but waste varies depending on an individual and so there is value to reduce it as its reduction is an effective way to increase profitability. This written work describes one of the engineering companies and how it eliminates waste that is Toyota.
Toyota was founded on 28th August 1937 in Toyota city as a manufacturing company. It is a worldwide automaker company that also provides financial services. Its present CEO is AKIO Toyoda and Chairman is called Fujio Cho. It is the third largest automobile company according to the 2011 OICA publication. It has its highest selling in the United States. Toyota regards waste elimination and energy reduction as its first priority in order to avoid damaging the environment. Majorly, it eliminates its waste by recycling it among many other ways of elimination. This has enabled it to grow from a small manufacturing company to the largest automaker worldwide alongside GM and Volkswagen.
Some wastes from Toyota’s end products create a threat by polluting the environment, which may in turn harm the living things around this polluted environment. In order to curb this, Toyota has adopted a mechanism where they design their products using raw materials that are easily renewable and also recyclable. This has been made efficient by using metals that are not heavy, that is using light metals which can easily be renewed.
In order to eliminate wastes Toyota has created centers for collection of waste products. At these centers, products that are old and not in use any more by customers are disposed off as wastes for recycling. To make this successful, Toyota indicates their contacts in their end products and dispatching centers for waste products. The customers can in turn use this indication for looking for nearest centers for dispatching the Toyota wastes or by contacting the Toyota recycling plants, which will in turn come and pick the waste.
Toyota also educates students from different institutions on the technology behind the recycling process of waste products from them. This enables the students to put this in practice at their homes consequently eliminating wastes. It also makes the students to be aware of the value of waste when recycled hence develop an attitude of eliminating it. This recycling technology is simple and does not require recycling machines nor can it recycle heavy waste materials like metals. To eliminate waste disposal that damages the environment, Toyota uses IMDS which shows the chemical composition in its accessories. This prevents releasing of products with high chemical composition that may cause negative side effects to human beings when disposed as wastes.
Wastes also arise due to overproduction of products than the customer’s demand. This has so far been identified as the worst form of waste as per the lean production. It makes most of the cash in the company to lie in the store. The cash may gradually be lost through wear and tear when products are not properly stored. This may be due to poor storage method, bad conditions and lack of up to date storage facilities. As Toyota does the best way to eliminate waste due to overproduction is to plan the packaging to the needs of the customers, producing products as per the needs of the customers and environmental conditions consideration. More alternatively overproduction of products can be lowered by making use of simpler and smaller machines for production rather than using super machines. Smaller and efficient machines stand a higher chance of producing fewer products with less waste than super machines. Also pertaining to labor a company should use less manpower as it lowers labor costs hence reducing the waste of overproduction in relation to cash.
Definitely wastes do arise due to transportation. This is when moving products from manufacturing plant to selling shops. Transportation is closely related to time. Sometimes goods that are manufactured from a company do not arrive at the retailer at the designated time as a result of transportation. Some products may be in bad condition due to long time transportation and even loose value due to failure in demand as demand goes in hand with durations.
On the other hand, transportation wastes a lot of energy from petroleum products. This waste of energy can be eliminated by using transportation objects that do not use petroleum products and are reliable like animals for short distance transportation and producing products that wastes less energy. This has enabled energy usage reduction per car by Toyota by 44% as from 2011 across Europe. Most likely each time of transportation products risk being damaged or lost. This defects due to transportation leads to leads to rejects hence waste arises. To reduce incurring all this waste transportation should be made efficient.
The 5Rs- Reuse, Refine, Recycle, Reduce and Recover energy have assisted Toyota to reduce in its manufacturing plants. This has led to waste elimination by 66% percent.
Some wastes released from manufactured products damage the environment. Toyota works at minimizing waste by reducing toxic emissions to the environment. This is by using ecological plastics that emit low amount of carbon (iv) oxide (CO2). Waste can also be eliminated by using natural existing fabric products like soy beans seats in North America, using plastics which are made from natural materials are easily renewable.
On the other hand wastes can be eliminated by reducing water usage. As experts say water shortage is going to increase in the coming 10 to 20 years. An example is Toyota where water has been reduced per car by 37% as from 2011 across Europe.
In automobile companies wastes also arise due to over processing. This is basically the extra steps that have no value to products. This can be related to the brain of a person when it is overworked; one becomes tired and hence works slowly. The same applies to manufactured products where using a product in a more complex manner does not add value to the customer but reduces it hence making it to become a waste. Toyota eliminates the waste due to over processing by considering whether it is of value to over processing a product to its end product or not and coming up with a more efficient way for manufacturing the same product.
An example of over processing waste in an automobile is over painting areas of a vehicle that can not be corroded. This can be avoided by standardization of products and educating employees on how to produce quality products without over processing.
Perhaps there is also waste that arises due to waiting. This is due to shortage of materials or one employee or manufacturing machine being slow and so making others to wait for it for them to commence. Definitely the employees have to be paid for the time spent in work but your customer will not pay for the waiting so you have to go at a lose. Toyota Company reduces this by balancing its production and reducing machine breakdowns by improving their reliability by using (TPM).
It has been noted that for a company to reduce the number of waste products care should be taken when manufacturing them. Products that are handled carelessly stand a higher chance of loosing more waste than those that are handled carefully. The best way that Toyota does to eliminate waste due to carelessness that arises from employees is by looking for intelligent employees. Intelligent workers do have the skills and knowledge pertaining to the work that they are doing. This enables them to handle their work carefully hence avoiding waste. Also the company gives respect to every employee. Respect to the employees increases their motivation to work. When a worker does work with motivation he or she does it willingly hence being perfect. A product that arises from such a motivated worker has fewer defects which reduce wastes. Furthermore, Toyota has a strategy where its workers work in team work. Working in team work enables people to share ideas, correct each other’s mistakes, empower each other, makes one to be cautious in everything he or she does, in so doing a better product results from team work approach which has less defects compared to the same product tha could have been made from a single worker. This in turn reduces waste.
Toyota also recognizes the defects that arise due to machine destruction which results to lots of waste. In so doing it has adopted a mechanism in their machines where if a defect arises in a machine it is detected and processing stops. This aids in reducing production of low quality products or products that have defects which are likely to go to waste.
Moreover, Toyota encourages the use of few raw materials, when few raw materials are used there is less waste production hence elimination. Although it is not possible to expect high quality production with fewer raw materials but Toyota has been successful with using fewer materials by selecting raw materials that are less but with high quality. This results in more production.
After reading this written work one should have an idea on how to eliminate waste, to avoid damaging the environment and conserve energy. In order to conserve the environment hazardous waste should be properly disposed to conserve the environment.