Scheduling and Analysis of Lot Production Lines in the Toyota Production System(Theory and Methodology)

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  • トヨタ生産方式におけるロット生産ラインのスケジューリングとその稼動特性(理論・技術)
  • トヨタ生産方式におけるロット生産ラインのスケジューリングとその稼動特性
  • トヨタ セイサン ホウシキ ニ オケル ロット セイサン ライン ノ スケジューリング ト ソノ カドウ トクセイ

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Abstract

This paper discusses the scheduling problem of lot production lines in the Toyota production system. A lot production line at Toyota produces parts in accordance with its schedule, which is planned in advance using lot sizes predetermined for each part. The lot size of each part produced in practice is the consumption of the part in the subsequent process in the time interval between the starting time of the previous production run of the part and the starting time of the next production run. As the schedule of lot production lines is determined in advance, in order to adapt to fluctuations in parts consumption, the lot size of the part is changed every time the part is produced. In scheduling lot production lines, the consumption of each part in the time interval between a certain production run of the part and the next production run need to be equal to the lot size predetermined for each part as much as possible. The reason is that the part inventory must be kept equal to the part consumption for the maximum time interval. Therefore, development of a schedule to reduce the total amount of the inventory of each part to a minimum is required. In previous studies, an approximate algorithm was proposed. In this paper, a revised method is developed to obtain a better solution. Moreover, using numerical examples, the properties of operation of the lot production lines controlled by the schedule based on the newly developed method are analyzed.

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