Created for: H.J.K. Used Toyota Dealership, LLC By: Custom Business Documents DO NOT COPY Prototype Specifications: Toyota Production System May 25 2010 For: H.J.K. Used Toyota Dealership, LLC Created by: Custom Business Documents
Created for: H.J.K. Used Toyota Dealership, LLC By: Custom Business Documents DO NOT COPY
Prototype Specifications: Toyota Production System
May 25
2010 For: H.J.K. Used Toyota Dealership, LLC
Created by: Custom Business Documents
Created for: H.J.K. Used Toyota Dealership, LLC By: Custom Business Documents DO NOT COPY
Table of Contents
Introduction .................................................................................................................................................. 4
Using this Document ................................................................................................................................. 4
Document Purpose ................................................................................................................................... 4
Definitions ................................................................................................................................................. 4
Phrases and Acronyms .............................................................................................................................. 5
Discovery ....................................................................................................................................................... 6
Network Infrastructure ............................................................................................................................. 6
Wide Area Network (WAN) ................................................................................................................... 6
Local Area Network (LAN) ..................................................................................................................... 7
Prototype Models ......................................................................................................................................... 8
PM-100.00 Management ..................................................................................................................... 8
PM-100.10 Interface ........................................................................................................................ 8
PM-100.20 Workflow ....................................................................................................................... 9
PM-100.30 Definition ....................................................................................................................... 9
PM-200.00 Accounting ...................................................................................................................... 10
PM-200.10 Interface ...................................................................................................................... 10
PM-200.20 Workflow ..................................................................................................................... 11
PM-200.30 Definition ..................................................................................................................... 11
PM-300.00 Manufacturers ................................................................................................................ 12
PM-300.10 Interface ...................................................................................................................... 12
PM-300.20 Workflow ..................................................................................................................... 13
PM-300.30 Definition ..................................................................................................................... 14
PM-400.00 Suppliers .......................................................................................................................... 15
PM-400.10 Interface ...................................................................................................................... 15
PM-400.20 Workflow ..................................................................................................................... 16
PM-400.30 Definition ..................................................................................................................... 16
PM-500.00 Dealership Franchises ..................................................................................................... 18
PM-500.10 Interface ...................................................................................................................... 18
PM-500.20 Workflow ..................................................................................................................... 20
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PM-500.30 Definition ..................................................................................................................... 21
PM-600.00 Sales and Marketing ........................................................................................................ 22
PM-600.10 Interface ...................................................................................................................... 22
PM-600.20 Workflow ..................................................................................................................... 23
PM-600.30 Definition ..................................................................................................................... 23
References .................................................................................................................................................. 24
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4 TPS: Prototype Specifications
Introduction
Using this Document
This document serves as a tool to articulate the requirements for the creation of the Toyota
Production System (TPS).
This is a comprehensive effort aimed at supporting Toyota’s production business model,
eliminate wasteful actions and spending, and increase the overall service level performance.
Document Purpose
The intent of this document is to provide prototypes and definitions to core processes
related to the TPS.
Definitions
Throughout the document the reader will encounter various figures and terminology that
are unique to the project. Prototype specifications will be written in an outline format (see
Figure 1.1). The objective is to hierarchically represent the business requirements and
relate the functional specifications directly to the respective business requirements they
enable.
PM-100
PM-110
PM-100.01
“PM” represents
Prototype Model
“###” represents
the requirement
group
PM-100.01.a
“n##” represents
the requirement
sub-group
“n##.##” represents the
requirement sub-group’s
specifications
“n##.##.a” represents the
requirement sub-group’s
specifications’ detail
processes
Figure 1.1. Definitions of the section outline pattern.
The prototype specifications are all workflow driven. The workflow is comprised of
multiple business processes and rules. Those processes, visually represented through
process maps, are composed of multiple tasks. Figure 1.2 depicts the most frequently seen
symbols and their meanings.
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5 TPS: Prototype Specifications
PM-###.##.x
Inventory Inquiry
Does this Hurt?
Find a Consultant
#
#
Business Process Step / Task
The process task contains several elements. The corresponding process is noted
(PM-###.##.x). The description of the task is truncated within the process as well.
END
START
Terminators
These shapes identify the start
and endpoints of a workflow.
Decision Point
This identifies when conditions indicate variances
in the business process flow. Normally the
conditions will result in a ‘positive’ or ‘negative’
outcome towards an alternate action.
On-Page References
More complex process flows may contain this symbol. It is a method to
connect the output of one task to another in an alternate location.
External Processes
These indicate where activities are
required that lie outside of the program.
Figure 1.2. Definitions of commonly used workflow symbols.
Phrases and Acronyms
This section will describe any commonly used phases or acronyms within the document.
Term Full Description Business Definition
PM Prototype Model This is a drafted model of the departmental production system interface and interaction.
TPS Toyota Production System
This is the name of the system being created for Toyota Motor Corporation.
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6 TPS: Prototype Specifications
Discovery
Network Infrastructure
The following diagrams illustrate the simple network infrastructure of Toyota Motor
Corporation of North America. They will be used to validate processes for data flow from
site to site.
Wide Area Network (WAN)
Toyota Motor
CorporationArea 1
New York
California
United States
Canada
Mexico
ISP1A
Public Network
Internet
RIP
QuebecMexico City
Totally Stubby
Washington
Area 0Ontario
Internal Subnet:
133.7.22.0 /23
External Subnet:
133.7.2.0 /30
Internal Subnet:
133.7.22.0 /23
External Subnet:
133.7.2.0 /30
133.7.99.0 /30
Internal Subnet:
133.7.6.0 /23
External Subnet:
133.7.99.8 /30
Internal Subnet:
133.7.42.0 /23
External Subnet:
133.7.4.0 /30
Internal Subnet:
133.7.41.0 /23
External Subnet:
133.7.4.0 /30
133.7.99.4 /30
133.7.2.2 133.7.2.1
133.7.99.2
133.7.99.1
133.7.6.1
133.7.99.10
133.7.99.9
133.7.42.1
133.7.4.2
133.7.4.1
133.7.41.1
133.7.99.6
133.7.99.5
Figure 0.3. The TMCNA high-level WAN organization.
The above figure illustrates the connection between the three major regions and the main
data site. IP addresses listed above are fictitious to protect the privacy of the company.
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7 TPS: Prototype Specifications
Local Area Network (LAN)
FireWall
Internet
Switch
Primary Server
Printer Share
Office Manager
Agent-10
`
Agent 1
`
Agent 3
`
Agent 7
`
Agent 5
`
Agent 6
`
Agent 8
`
Agent 4
`
Conf Rm 1
`
Agent 2
`
Agent 9
External Router
OfficePrinter
LAN BACKBONE
Figure 0.4. The TMCNA typical LAN office setup.
The image describes the typical office setup for each corporate office and franchised
dealership. Each office varies depending on location and resources; however the basic
infrastructure stays the same within all of North America.
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8 TPS: Prototype Specifications
Prototype Models
PM-100.00 Management
The Management is one of the primary processing arms of the entire TPS which describes
the manpower involved. They provide the list of employees including the supervisors and
mechanics whether they are full-time, part-time or contractual within the manufacturing
site. This part of the system keeps users up-to-date in the available manpower for a certain
amount of time through various dashboards.
PM-100.10 Interface
The following prototype will give the user an insight about the list of employees under
the TPS, which can be used in determining and evaluating their working capacity on the
allotted job order. This includes the supervisors or personnel who will be allowed to
replenish the needed supplies, machineries and/or additional workforce.
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9 TPS: Prototype Specifications
PM-100.20 Workflow
PM-100.30 Definition
Task Description Importance
PM-100.20.a This is the quick view of needed information for an employee which might have a flagged report on a certain parts issue.
PM-100.20.b This can have the user reply to reports which needed a solution and have it sent back to the appropriate employee
PM-100.20.c The user can set-up a meeting for an individual employee - or-
PM-100.20.d can submit an occasional evaluation report for that specific employee
PM-100.20.e PM-100.20.f
The user can only view information regarding a searched employee or position.
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10 TPS: Prototype Specifications
PM-200.00 Accounting
The Accounting is one of the primary processing arms of the entire TPS. They provide the
accountability of the purchasing and acquisition of the parts and supplies that is required to
keep the production of the vehicles in the factories. This part of the system keeps users up-
to-date in the financial and physical requisition (inventory) of the parts and needed
equipments through various dashboards.
PM-200.10 Interface
The following prototype will focus on the interactions between a managed user and the
Toyota’s inventory of parts, supplies & equipments as well as the purchased orders that
was shipped and will soon be arriving.
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11 TPS: Prototype Specifications
PM-200.20 Workflow
PM-200.30 Definition
Task Description Importance
PM-200.20.a This is the quick view of a needed part with corresponding control number as well as physical count of that particular item available in the factory. A view of all parts can also be done, to query on how many is still on stock or whether a repeat order is needed on some of them.
PM-200.20.b The parts stock physical count cannot be edited but instead if it doesn’t have enough a PO form can be filled up and be submitted for ordering.
PM-200.20.c The supplies department will reply on when and what can be delivered as per PO form.
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12 TPS: Prototype Specifications
PM-300.00 Manufacturers
The Manufacturers are one of the primary backbones of the entire TPS. They provide the parts
required to keep production of vehicles steady in the factories. This part of the system keeps
users abreast of the current factory workload and dealership demand through various
dashboards.
An assumption is made regarding the user that authentication was completed prior to entering
this screen.
PM-300.10 Interface
The following prototype will focus on the interactions between a managed user and the
manufacturer(s).
File Edit View Navigate Search Help
|
+ My Manufacturers
MFC 1
MFC 2
MFC 3
MFC 4
MFC 5
MFC 6
Alert Center
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Aliquam vulputate metus ac ipsum
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1 2 3 4 5
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Run Report
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Figure 3.1. The Manufacturer Prototype home screen.
Descriptions:
1) Basic Navigation – The toolbar for navigation will allow for simple and advanced
features of the TPC program operation.
2) Quick Actions – These are user/administrator configured buttons assigned to
specific TPS Manufacturer based actions.
3) Manufacturer File Manager – The navigation of all manufacturers within the
window is done by searching the file manager. It is setup in a file tree or directory-
5. Manufacturer
Task Status
1. Basic Navigation
7. Task Selection
Details
6. Manufacturer
Overall Status
4. Alert Center
3. Manufacturer
File Manager
2. Quick Actions
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13 TPS: Prototype Specifications
based format that is easily recognizable to the user. Making a selection within the
file manager will populate other screens with relevant data.
4) Alert Center – The alert center displays the top four alerts and their levels of
severity. Population of these alerts is dictated by an alert rule set that is modifiable
only by authorized personnel.
5) Manufacturer Task Status – This status window populates the tasks associated with
each manufacturer according to priority and time of creation. It follows the kanban-
style of project management.
6) Manufacturer Overall Status – This status window gives the user access to important
reporting and budgeting tools in relation to each manufacturer.
7) Task Selection Details – This is the extension of the Manufacturer Task Status
window. When a task is selected, the information stored within each task is
displayed here.
PM-300.20 Workflow
The Manufacturer workflow depicts the high-level steps involved in the Manufacturer
management process.
User Have Admin
Rights?
START
PM-300.20.b
Navigate File
Folders
User Navigates
Main WIndow?
PM-300.20.c
User Selects
Manufacturer
PM-300.20.f
Validate User
Changes
User Want to
Expand Alerts?
PM-300.20.d
Selected
Manufacturer
Data Populates
in All Windows
PM-300.20.e
User Manages
Manufacturer
Data
PM-300.20.a
Populate Default
View
User Changes
Valid?
Yes
NoNo
Yes
PM-300.20.g
Open Alert View
Yes
PM-300.20.h
Populate Main
Window, Details,
and Status
Window
User Runs Status
Report?
No
Yes
No
PM-300.20.i
Query and Run
Status Reports
Yes
User Chooses
Quick Action
Task?
No
PM-300.20.j
Perform Quick
Action
Yes
END
No
Figure 3.2. A simple workflow of the Manufacturer Prototype Model.
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14 TPS: Prototype Specifications
PM-300.30 Definition
Task Description Importance
PM-300.20.a This process contains the commands for the initial load of the Manufacturers Screen. It will load all non-static windows and replace the data with the currently selected task.
High
PM-300.20.b This process involves the navigation of the file tree for the selection of processes within the manufacturer navigation area.
High
PM-300.20.c This process involves the selection of a manufacturer from the file tree. It is not essential to the functionality of this prototype.
Low
PM-300.20.d This is where the selected manufacturer causes a repopulation of all non-static windows within the screen.
High
PM-300.20.e An authenticated administrator or editor may modify any manufacturer data within this process on the status windows.
High
PM-300.20.f This process will validate the user’s data entry using a given set of standards for the prototype.
High
PM-300.20.g This process initiates the opening of a separate alert window. It contains larger details of alerts that are listed in the alert status area.
High
PM-300.20.h This process occurs when a user traverses dates within the task status window. All status windows update with the relevant data for the visible dates.
High
PM-300.20.i This process runs the status reports that are formatted as dictated by the department standards. Available reports are window queries, Excel spreadsheets, CSV, Access databases, and text files.
High
PM-300.20.j This is a super-process that calls the separate functions that are pre-programmed into the quick access areas.
High
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15 TPS: Prototype Specifications
PM-400.00 Suppliers
The Suppliers are the second part of the TPS backbone. These companies provide the
necessary parts for construction of factory items by internal Toyota factories and other
manufacturers. This part of the system alerts users as to the status of resources available to
manufacturers. It also allows for goods to be requested directly from the Suppliers
themselves.
PM-400.10 Interface
The following prototype will focus on the interactions between a managed user and the
supplier(s).
HOME REPORTS REQUESTS
12
34
5
View Report
Internal: 120,842
Quick View
Top Needs
Manf. 1: 133,323
Manf. 2: 149.128
Manf. 3: 170,622
Manf. 4: 198,334
Supplier Supplington
Site Address:
Point of Contact:
Comments:
Phone:
Fax:
5 Anywhere Dr, Iota, DE
Mr. McSupplies
Comments about the client are stored here...
(555) 555-5555
(555) 555-5555
Available Tasks
Create a Report
View AvailableWidgets
Order Widgets
Make a Request
Figure 4.1. The Supplier Prototype home screen.
Descriptions:
1) Tab Bar – A tabbed section unique to each TPS screen. The Supplier screen has 3
defaulted tabs available – Home, Reports, and Requests. Each tab allows for
different functionality within the Supplier TPS.
2) Quick Reports – Both text and graphics based reports are located on the Home
screen. These provide a quick look into the immediate needs associated with
each supplier.
3) Search Tools – The search bar within the TPS allows for searching within the
entire network for any relevant data.
4) Supplier Information – The Home screen allows a user to view or a super user to
modify information recoded with the TPS database. This data refreshes when a
new supplier is selected.
3. Search Tool
1. Tab Bar
2. Quick Reports
4. Supplier
Information
5. Task
Shortcuts
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16 TPS: Prototype Specifications
5) Task Shortcuts – This section has button shortcuts to some of the more common
tasks that a user would commit while within the Supplier TPS screen.
PM-400.20 Workflow
The Supplier workflow depicts the high-level steps involved in the Supplier
management process.
User Have Editing
Rights?
END
START
PM-400.20.e
User Enters
Search Data into
Search Bar
Conduct a
Search?
PM-400.20.f
Display Search
Results
PM-400.20.d
Perform Shortcut
Task 1-4
User Want to Edit
Supplier Info?
PM-400.20.c
User Enters
Modified
Supplier Info
User Perform
Shortcut 1-4?
PM-400.20.b
Populate Task
Shortcuts
Yes
Yes
PM-400.20.a
Populate Quick
View
Yes
Yes
NoNo
No
No
Figure 4.2. A simple workflow of the Supplier Prototype Model.
PM-400.30 Definition
Task Description Importance
PM-400.20.a This process involves the querying of pre-fabricated reports for view on the Home screen.
High
PM-400.20.b This process populates the program or user generated settings for the Supplier Task Shortcuts specific to each supplier.
High
PM-400.20.c This process enables authenticated users to modify stored information within each Supplier screen
High
PM-400.20.d This process involves the selection of a Task shortcut by the user. The generated shortcuts will each have their own process assigned by program automated tasks.
High
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17 TPS: Prototype Specifications
PM-400-20.e This process takes the data entered by the user into the search bar and conducts a search.
High
PM-400-20.f All results derived from a user search are displayed by this process.
High
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18 TPS: Prototype Specifications
PM-500.00 Dealership Franchises
For Toyota Production system a car dealership, and vehicle distribution center is the main
business that sells cars at the retail level. Its sells depend on the dealership contract with an
automaker or its sales subsidiary. Dealership franchises involve employing automobile
salespeople to do the selling. It may also offer maintenance services for cars; employing
automobile mechanics; stock and sell spare automobile parts; and process warranty claims.
PM-500.10 Interface
This interface will provide users the necessary tools needed to get car dealership their
inventory. Users may look up inventory or dealership information, update inventory,
see information pertaining certain cars or dealership, and user accounts. The main
purpose of this interface is to allow users to quickly and efficiently look up necessary
information to dealership franchises.
Figure 5.1. The Dealership Franchise Prototype home screen.
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19 TPS: Prototype Specifications
Descriptions:
1) Menu Tab
a. File
i. New
ii. Open
iii. Save
iv. Print
v. Share
vi. Close
b. Transaction
i. Sales
ii. Accounts
iii. History
c. Search
i. Search Customer History
ii. Search inquiries
iii. Inventory
d. Security
i. Creates various types of account like Admin account, User
accounts.
ii. All security inquires
e. Reports
i. Reports of different types of analysis on per day basis as well as
period basis (monthly Reports, Annual Reports).
ii. Prints Bills of customer when there for transaction.
iii. Inventory management
f. Help
i. Translation option (Spanish, French, and etc.)
ii. Help Hotline and Website Help
iii. FAQ
iv. Help inquiries
2) Sub Menu Tab
a. Add/Edit Cars
i. Insert, edit, and delete new cars
ii. View Cars Pictures
b. User Defined
i. User Information
ii. Switch users
iii. Users Records and Reports
c. Inventory
i. Inventory Management System
ii. Location of Cars
d. Car Look-Up
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20 TPS: Prototype Specifications
i. Look up description
ii. VIN, Make, Model and etc
e. Set-Up User
i. Set up sale
ii. Set up group sales
PM-500.20 Workflow
The Supplier workflow depicts the high-level steps involved in the Supplier
management process.
Figure 5.2. The Dealership Franchise Prototype model.
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21 TPS: Prototype Specifications
PM-500.30 Definition
Task Description Importance
PM-500.20.a Users Enter Home Main Screen High
PM-500.20.b Users utilize system to establish tab High
PM-500.20.c Users see data that’s necessary to execute work. High
PM-500.20.d Admin controls and plan data system High
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22 TPS: Prototype Specifications
PM-600.00 Sales and Marketing
For Toyota Production system the sales center is the main business that sells cars at the
retail level. Its sells depend on the dealership contract with an automaker or its sales
subsidiary. Sales involve employing automobile salespeople to do the selling.
PM-600.10 Interface
This interface would allow users to make sales and sales related transactions. Users can
make sales to dealership and have the ability to input all the necessary information
needed to make that sale possible. The user would have a work area to change interface
and transactions quickly.
Figure 6.1. The Sales and Marketing Franchise Prototype home screen.
Descriptions:
See PM-500.10: Descriptions for more details.
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23 TPS: Prototype Specifications
PM-600.20 Workflow
The Sales and Marketing workflow depicts the high-level steps involved in the
management process.
Figure 6.2. The Sales and Marketing Prototype model.
PM-600.30 Definition
Task Description Importance
PM-600.20.a Users Enter Home Main Screen High PM-600.20.b Users utilize system to establish tab High
PM-600.20.c Users see data that’s necessary to execute work. High
PM-600.20.d Admin controls and plan data system High
PM-600.20.e Users executes and modifies sales information Medium
PM-600.20.f Enables users to perform short cuts Low
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24 TPS: Prototype Specifications
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http://www.gm.com/copyright/http://www.standardandpoors.com/ratings/articl
es/en/us/?assetID=1245209798004
ICMR. “Knowledge Management Practices at Toyota Motors.” Pub 2005
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MIT Lecture. “The Toyota Production System. High Quality and Low Cost”
http://web.mit.edu/2.810/www/lecture09/14.pdf Retrieved April 25, 2010.
Naughton, K. (2010, March 30). Toyota says discounts may boost march u.s. sales 35%
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http://www.businessweek.com/news/2010-03-30/toyota-says-march-u-s-sales-
rose-up-to-35-in-march-update1-.html
Reuter. TOYOTA MOTOR CORPORATION (TM)
http://www.reuters.com/finance/stocks/companyProfile?rpc=66&symbol=TM
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Toyota Technical Center. Toyota CAD eXchange (TCX) Mailbox System for Electronic CAD
File Transfers. http://www.fastsync.com/ttc.htm Retrieved April 25, 2010
Created for: H.J.K. Used Toyota Dealership, LLC By: Custom Business Documents DO NOT COPY
25 TPS: Prototype Specifications
Toyota Technology. “ ITS.” http://www2.toyota.co.jp/en/tech/its/index.html Retrieved
April 25, 2010