1. Topic-
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| Use Pull Systems to Avoid Overproduction |
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2. Content-
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| Pull systems can eliminate the seven forms of waste found in work
activities. The strategy is to employ once piece flow in production
processes where Just In Time is being employed. Then to have each
process pull from the previous one in a sequence that progressively
completes the order that is to be received by the customer. Waste
such as inventory cannot all be removed from the processes but can
be better controlled with the use of Kanban systems that will limit
the amount of inventory to the processes based on the customer demand
rate. Even though Kanbans help flow in the processes it is still subject
to continuous improvement methods to eventually reduce inventory to
zero. Once this is accomplished the pull will be a pure form of one
piece flow. |
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3. Goals: Aims/Outcomes-
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1.To engage the learner in a gradually progressive format to embrace
the Toyota Production System principles.
2.To make the learner less fearful of change in their work environment
and to see their involvement in creating change as a positive to their
future in being a contributor in the success of the company they are
employed with.
3.To have the adult learner to understand the use of pull systems
so when they go to work with a company that will use this method in
their processes they will be trained to work in this environment and
can do so with foreknowledge of how to maneuver in it confidently
in performing their job. |
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4. Objectives-
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1.To generate a desire in the adult learner to know more about the
Toyota Production System plus give them a different outlook on the
manufacturing business as something more wholesome than they have
ever been involved with before.
2.To minimize fear in new workers or prospective employees working
in a TPS environment by having knowledge of the system.
3.To make the adult learner a viable employee or a candidate for hire
with any of the Toyota companies in the area. |
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5. Materials and Aids-
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| Powerpoint presentation, Modeling of some of the topics, visual
aides, handouts, role play activities with simulations. |
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6. Procedures/Methods-
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A. Introduction-
1.I will introduce the topic with the PowerPoint presentation showing
the TPS House Diagram and explain it's strengths
2.I will lead it into the left pillar of the House and explain that
pull systems are well linked with the contents of Just In Time
3.I will then stress the nature of pull in it's most simplistic form
of our own daily life to create a mental picture with the learner
with the intent that every time the word pull is mentioned they grasp
it with the picture within their mind. |
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B. Development-
1.I will present a counterpart to the pull system known as push
and explain it's onetime greatness through the example of the Ford
Motor Co.
2.I then will exploit the push system as to it's costliness to maintain
as well as inability to sustain itself.
3.I will note the downfalls of the system through PowerPoint and an
activity using push.
4. I will introduce the Toyota Production System from the point in
time that Taiichi Ohno was given the responsibility to develop a system
that would bring the Toyota Motor Company up to date with Ford.
5. I will then continue brining up the history of the development
of the system to the point Ohno is utilizes continual flow from the
Ford Motor Co. and the supermarket systems of the US to replenish
goods on the shelf for customers.
6. I will demonstrate the replenishment of stock on the shelves and
explain how it is used in the pull system.
7. With PowerPoint I will stress that the pull system is not a pure
one until it is done with one piece flow and no inventory. The Goal
is to get to zero inventory with continuous improvement methods. |
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C. Practice-
1.There will be an activity in which the adult learners will create
smiling faces utilizing the Push method of production and all that
goes with it.
2.I will also engage the learners by utilizing the the smiling faces
activity but this time utilizing one piece flow and pull.
3. Finally I will take the class to the lab and put them in a more
real life setting to employ one piece flow and Kanban systems. |
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D. Independent Practice-
For this one 45 minute class with no known future class yet in existence
there will be no independent practice.
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E. Accommodations (Differentiated Instruction)-
1.The accommodations will be a classroom environment in a group
setting.
2.Final activity will take place in the companies instructional lab
area.
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F. Checking for understanding-
1.I will observe how well the learners are engaged in the activities
to help me determine whether they are understanding the points I am
instructing.
2.The types of questions asked will let me know if they are following
the instruction I am giving.
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G. Closure-
| I will end the class with a game that will test their knowledge
of what they learned in a competitive environment. |
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