Lean Manufacturing Example Toyota Plant Kentucky

[UnitedPebbles]

Eh, Toyota should know the risks it undertaking for open a plant in such a place. I would at least study the area before open one.

Did you watch rise of planet of the apes? definitely a worthwhile re-thinking of human behavior and emotion.

Best place in the region would be Alabama. Best place in the region to sell cars would probably be Texas.

[UnitedPebbles]

@UnitedPebbles

Nevermind, I thought this video was for the Mississippi plant. Hahaha

Toyota will regret it.

[TheBestRecyclers]

we are the best recyclers and we buy all types of scrap metals and alloys such as brass, copper, stainless, inconel, hestalloy c and x, nickel, carbide, and more. we also buy car, boat, and rv batteries as well as watch batteries, we also buy whole forklifts and machines and all types of IT equipment like servers, computers, motherboards and more.

[Xquire]

@TheBestRecyclers

My pal is the largest exporter in USA Autos, Mechanisms to Venezuela. We would collect 1000's motors, trans, everything.

We would fill up a 10 x 10' bin in 20 minutes with nut and bolts alone from recycling and R&R repairables

Auto Parts, scrap, rebuildable motors, purchase 100's of motors daily

Start out daily with 50k or 100k hit all the yards, with 300 employees, trucks waiting to unload huge bins of Trans, Eng, rear ends ETC at the Plant

55 gal drums brass etc.

[Xquire]

@TheBestRecyclers

Their aluminum shredder was non stop all day all night, they would pop open the Catalytic Converters save the contents.

[hojoleon]

do they consider these workers american workers

[hojoleon]

di they cinsider these workers american workers

[grybold]

I hated working in manual labor! I'm so glad to see robots doing all of this stuff now so that I can sit at home and watch TV ! Thanks robots! :)

[bestwayusa1]

Yet They do it in USA, illegal donation came up during a parliamentary budget committee meeting last week. Maehara initially said he didn't know about it, but later acknowledged that his office accepted a 50,000 yen ($590) donation from a longtime supporter, an ethnic Korean resident of Japan whom he had known since childhood, and apologized.Japan's political funding law prohibits lawmakers from accepting donations from foreigners even if they are Japanese residents or born in Japan

[999Atwood]

Lean Manufacturing is destroying a lot of companies. In their greed for more bottom line they are producing a lot of junk. The old studs who built these companies had damn good reasons for EACH STEP in the process. Short cutting is not cheaper in the long. The cheap supplies we now use in our battery products = JUNK. Short term thinkers are in charge of most of these operations.

[390merc65]

when i hear [lean manufacturing] ..i cant help but think that is toyota's way of letting out some safety devises on their vehicles...i know i will never buy a toyota ..or any import..glued together here or not

[UnitedPebbles]

@390merc65

I heard they switch supplier and forgo quality inspection. Apparently, the supplier in Japan wanted a higher price and Toyota see them as not efficient as time consuming, costly, and other things so they switched to a closer supplier. But the standard is not the same and not consistent. The new supplier credibility is not as good as the old supplier. If you read theory M, there are that "clandestine" relation that Toyota forget : loyalty, good will, sacrifice, etc..

[ZorrisPorris]

Me caga La UDEM!!!

[Sp1RoXx]

Mr Knox is making this video famous. :3

[sw7bf4ever]

it IS really bad quality...

[aznxdope]

Wow i could have videotaped this with my ass.

[gingerfish16]

@aznxdope

[gingerfish16]

@aznxdope are you chad nishida?

[midgetmao]

@aznxdope stfu chad.

[aznxdope]

@midgetmao 240p sucks so bad. This videos so bad I cant even watch it on regular my computer.

[rukiarocks]

@aznxdope Wow you're ass is pretty huge if it can go high up in the sky. Inherited from your mother, I presume?

[rukiarocks]

I own a horse. This video gives me an erection.

[meattube4u33]

Over last 20 years both America and japan have had inflation but the change in value is HUGE where 1 unit of our money was worth 100 of thiers it is now only worth 10, imports used to be much less expensive than domestic but not anymore and in the years to come your average import will cost far more than a comparable domestic, and thats why toyotas are now built here in America by pissed off hungover drunks that make half what union workers do and they fucking hate it, quality will suffer

[seansdoesntdoweed]

'Hey make sure you put those sticky pedals in there good!" ahahaa

[Airsoftrisupetteri]

@seansdoesntdoweed There has been a study that in most cases the driver pushed gas instead of brake anyone who has driven a car knows that eventhough you are flatout and you push the brake the cars engine dies...

[seansdoesntdoweed]

@Airsoftrisupetteri it was just a joke :p

[danielalien]

So americans. Since you can't beat the japanese on quality or price, you need to bitch about you being the first to invent most components on the modern automobile? Pathetic.

"Hurr durr, I want an American car built by Fred Flintstone who thinks using efficient engines, lightweight materials and independent suspension makes you a homosexual!"

[mrzeolite]

Oh and lean consultants need to die already, implementing a system without understanding the product equals fail 95% of the time. Most consultants are worthless from what I've seen. Buzzword whores.

[Rico8458]

where does toyota make lexus in the usa?

[bestamerica]

'

robotic make car / truck then must be cheaper to sell it,,,

NOT too much

[6489532ab]

The Toyota production system is based on crystal meth. Hence the need to poka yoke EVERYTHING. If a meth monkey can screw something up they will.

Shameful Japanese managers encourage the distribution of meth in there facilities. Take away there meth and there productivity will drop like a rock.

[amshaegar1]

I was a Quality Technician, a 5S/Lean-coordinator, and now I am a Supervisor at the same Company that has plant in, for example, Mexico too. And We supply Our products to Toyota.

But these guys know something, that We all need to learn :)

[AJstar9]

recall

[bboybiogrind]

how many computers operate this plant

[TheTraevance]

Hm... Well my friend just went to KINETICDIECASTING . com and her got very quality services! Maybe you should try it too!

[videoslacker]

What I find incredibly funny is that people don't realize that the so-called "superior" Japanese method of manufacturing is in fact American in origin. You people think I'm nuts? Look up a guy by the name of Edward Deming. The Japanese hold Deming's teachings in very high regard.

[Allante715]

@videoslacker

Japanese automakers really never come up with original ideas. They just make a European or American design better.

[cebokisha]

@Allante715

That is false!

It has been statistically proven that Japanese automakers create more inventions AND innovations than any other European or American country. Check "Strategic vs Evolutionary Management - A US vs Japan Comparison" book and you'll see what I mean.

[Allante715]

@cebokisha Did the Japanese invent the fuel injector? internal combustion engine? Headlights? Turn Signals? Adjustable Steering Column? Disk Brakes? Cruise Control? Electric Windows? Electric Ignition? Spark Plug? Muffler? Odometer? Seat Belts? ECT...ECT....ECT

Give me an example of a Japanese invention or innovation that is on the majority of automobiles. Must be an original invention not an improvement. You can go tell me to read a book but the least you can do is give examples.

[avsararas]

@Allante715

Japanese invented Katana

[cebokisha]

@Allante715 Ok. I was reffering to more general domains, not just car manufacturing, but as I know of, Subaru invented the electrical transmission, Honda invented the piston ring, valve lifts, timings, something the like (I'm not very good at mechanics, I'm sorry), Toyota invented the automatic looms, plus I might be wrong, but Nissan invented the first "plug-in-and-drive" system? :) And let's not talk about the corporate strategies which made everything possible. Just a few examples,that's all

[roastoo00ooveges]

@Allante715 Yeah well New Zealand was the first country to include a spare wheel with a vehicle. before this all you got was a tyre and tube! American standards actually slowed down some safety inprovements to vehicles. Like seatbelts,airbags, impact bumpers, roll-over protection and many items more. The Japs actually invented electric windows and air con. The Germans disc brakes, airbags, ABS and oh the auto car itself.

[cebokisha]

@videoslacker

I just love Americans who like to take credit for all the good things in this world...

Edward Deming was the developper of Quality Control Management. But building a car is more than quality control. And Kaizen is much more than that also. And let's not forget that E. Deming conducted his work in Japan, where he worked with Japanese, who later improved whatever he had initially developped... I don't like you implying that Japanese car manufacturers owe everything to E. Deming.

[videoslacker]

@cebokisha The sad thing is that Deming went to the big 3 first, and they basically laugh at him(I'm not kidding). So he took it to the Japanese and the rest is, as they say, history. Ford was about the only one that listened to Deming after that. GM and Chrysler...not so much.

[lrossi888]

@videoslacker I also find it funny when people tell you to buy American, not Toyota or Honda, even though all of their cars sold in the United States have been made here in the US since the 90's.

My 1993 Camry was made in Kentucky.

[lrossi888]

@lrossi888 Not sure about Honda's, I was referring specifically to Toyota's.

[mrzeolite]

@videoslacker But it's Americans lack of discipline and poor leadership and management that makes Japaneses perfection of these "known" manufacturing methodologies unique and profitable. We blindly implement LEAN tools without understanding inherent characteristics that make them work in Japan.

[videoslacker]

@mrzeolite Sir, that what you just said automatically makes you racist in my mind. Some of the hardest working people I've ever meant and worked with were American. If the Japanese are suppose to be so freaking superior and disciplined, why did they call the US to help them fix their obsolete nuclear plants when that earthquake hit? I thought Japan was suppose to have a "superior" infrastructure. Sorry for getting pissed, but its about time someone lay the hammer down on this "hate the US" crap.

[mrzeolite]

@videoslacker You're comparing two completely different things here dude. Let's keep the argument to manufacturing in the 21st century at least so we are on the same playing field. Fact is Japanese work ethic (not accepting "good enough" attitude) shows in their product quality. Before you hit me with an emotional response go out and compare a Toyota vehicle made in Japan (Yaris, Prius, FJ, Scions) to those made in US (Camry, Tacoma, Tundra, etc) and you will see major differences in quality.

[videoslacker]

@mrzeolite Sir, I still label you a person that is basically saying that a nation of roughly 300 million are lazy. That is blatant generalization and racism no matter how you look at it(emotional or not). Are you saying that Americans cannot make good stuff at all? If that is the case, then I can name two hand built US made cars that truly are high-end machines; The Ford GT and the SSC Ultimate Aero(I call it the speed demon). Oh, and look up Nelson Racing Engines while you're at it.

[UnitedPebbles]

@videoslacker

He said they imposed a higher quality there; not the kind of "good enough" patted on a shoulder and move on like in Kentucky or Canada. That is why there are parts shortage, because quality doesn't mean quantity. And quantity often are cheap or risky or lawsuit or billions of dollar in damage for the company, priceless for the consumers. Trust and brand cost time and money or a lot more in money!

[SirishT]

As far as I'm concerned Toyota is as American as the Detroit companies.

[MrTwitcher216]

@SirishT bullshit jackass toyota is about as american as the computer you're using right now. Fuck toyota, down with toyota!!

[SirishT]

@MrTwitcher216 Hey pal, my toyota has a fucking vin number that starts with 1 while my friends all-American ultra patriotic pickup truck with all the bumper stickers to match starts with a fuckin 2. Do you even know what that means? It means my car was made by American workers.

[MrTwitcher216]

@SirishT Hey pal my FORD's vin number starts with USA you fucking moron. SHUV YOUR TOYOTA UP YOUR ASS YOU USELESS PIECE OF SHIT!!!!!! GO SUCK TOYOTA'S DICK YOU QUEER.

PAL lolz. :)

[SirishT]

@MrTwitcher216 why are you trolling a toyota video if you don't even like them and why would you care what someone else drives anyway you cocksucking faggot? Do you get a thrill from starting "fights" on the internet? Is that how you spend your free time? Get off your computer and get a fucking life you dork. I'm done responding to you.

[Allante715]

@SirishT

Its alot more then that. You really have to look at where the parts come from to assemble those vehicles and were the profits go. Hyundai for example assembles a few cars in America but those cars US content are in the 30-40 percents. The most amount of auto manufacturing jobs comes from suppliers not from the actual assembly plant.

[AJstar9]

and your money gos where japan

[Allante715]

@SirishT

You just keep thinking that.......

[jsoroushi]

It looks like other auto assemble lines. I could not find lean concept applied in any part of this video. If you know, please share with me.

[thedemolisher86]

There is one piece flow occurring. You have to treat each work cell as a customer. There is no team member working on more than one vehicle before the finished product moves to the "customer." Also, if you notice the colors of cars, it is evident that they produce according to variety which is essential to a level production.

[jsoroushi]

Thanks for the info.

[petrocelly]

damn I love those bumper stickers DONT BUY IMPORT. but the IMPORT is made in here !

[RYwiccan]

Not all.

[petrocelly]

I only say that most of the import is build in america. Premium models are build in japan. Its easy to see how many models are build in here, u can tell by the last recall. Looks like americans cant even follow up japanese instruction to produce and assemble the cars, that's really sad. All what americans can do is unionize !

[TOMandALLEN]

go CARDS!!!

[Metalman405]

C-A-R-D-S!!!!

[dwerke]

Quite many africans employed there!

[FordCopChrist1995]

They're americans not africans.

[roygbiv330]

wondering whether there were any kaizen processes in this video?

[pivkan]

kaizen process would mean that an improvement was shown.  There was no "before" and "after" footage shown. Don't quite know what you mean. This is just an overview of the plants within TMM Kentucky.

[Timx4]

I thought is KFC

[attie3]

i wish we could have a Toyota Plant in michigan god knows we need it thank you be three ass holes

[ricardoermm]

i worked there for 18 months !!

[carlocardillo]

and what was it like

[ricardoermm]

i was impressed how easy is to build a car...57 secs per car, thats incredible

[vmp001]

and why you left them???

[ricardoermm]

mmm. It was a technical traning ... tried to got hired but I couldn't :(

[vmp001]

sorry man!!! best 4u

[ilovenissan]

why do all the workers in this video look so pissed off

[struckync]

they realized all american money is going to japan.

[carlocardillo]

there not pissed off there working.

[carlocardillo]

there not pissed off there in work and there paid to do a job not be be happy.

[vova200]

make me a car plz

[chiffert0]

2.- The TY way it's not a matter of nationality it's a matter of systems and making them work.

[chiffert0]

3.-Unions----no commnents on that, ok, maybe one...toyota doesn't have them, or they are still manageable. while a GM union worker earns around $27 USD/hr or more as an average and if they work overtime and they could earn upto $70 USD/ hr.

[chiffert0]

in other words, just to compensate for all of those benefits, the American car companies, have to inflate the price tag on their cars by and average of $3,000 USD per car. Not to mention that engineering, Human resources, quality, materials, and all of the other departments in their manufacturing plants HAVE to ask for permission to the Union to do the simplest thing,

[vmp001]

you´r right...thats because these greats company are going to loose all what they build on the past......is a shame. here in mexico GM pay 27usd at day, but thats no the problem, the problem begins with low quality and bad designs, this why Toyota is the best automotive company around the world, the key is innovation. I hope some day you (America) build again the best cars on the world with the classic companies (Ford, GM, Chrysler). see you!!!

[manlyday]

Yeah, almost ten years ago I read my dad's collection that was technical reading for engineers back to 1981, the author, a Japanese reflected the operation of Toyota from early 1900s to the end of 1970s, at that time they had discovered such way to improve process but keep focusing on building cars, and at that time they're beating with Nissan, the largest car producer of Japan in 1980. Those spirit has almost been inherited from then till now. Incredible...now they succeed

[FordCopChrist1995]

Not Ford though. Their quality has improved termendously over the years and they didn't need a bailout. Their quality has met Toyotas and Hondas in fact.

[scottstrike10]

not to sound smart but over here in europe the ford transit van is the biggest heap of dirt around,,,,everything goes wrong with them...

[chiffert0]

Excuse my intervention, I'm a lean manufacturing consultant so I'd like to post a comment so the other people that see this video can understand little bit better about lean.

1.- Toyota also has plants and / or suppliers in Mexico, and the quality it's still great.

[nycsharp]

If toyota could come to the US and compete, why can't GM, ford or chry go to Japan and do the same. The comsumer wants more for their money and the Japs seem to deliver. This is a global econamy and if you can not compete... goodbye!

[carlocardillo]

as your new president says American jobs for American.that rules out japan.

[rudder11]

China is going to kick you ass

[rudder11]

Kentucky go ahead and build another zero

[rudder11]

I know you need the money,so build toyota.

All car builders all do the same thing

Just build a car.Today cars are just cars..

[rudder11]

You got to walk out of the plant ,with you head down,you just made another piece of shit

For Japan..........

[rudder11]

I hate to say I'm from Ashland Ky

To go this low,working for Japan shame on you

[001jd]

at least the japanese employ thousands of people in both canada, and the US, while at the same time GM, Ford build their garbage cars in mexico, i think it is more patriotic to buy a car that was built in your own country. American companies with their huge trucks, stupid CEOS and greedy unionized workers are a thing of the past baby!!

[rudder11]

And you can kiss my ass

[001jd]

typical american hillbilly, knows it true, cant think of anything smart to say so resorts to violence and insults.

[rudder11]

Your just a fucking kid, I'm almost 56 what

The fuck do you know, other than wondering why your dick gets hard.Happy Health care when you get older fucking piece of shit.

And Canada don't have that good of free insurance.But I like Canada kids are

The same ever where......you little prick

[EvolutionIXRR]

i'm an autobody painter and would like to know what size of needle tip does the robot use? What brand of paint?

[hadeskngofhll]

amazing what kaizen can give you thats why toyota is almost leading in car Manufacturing

[lemonlad7]

What do you mean almost. They ARE leading in the car manufacturing market.