Toyota Motor Manufacturing, Kentucky, Inc. (TMMK) …

Toyota Motor Manufacturing, Kentucky, Inc. (TMMK) is Toyota’s largest vehicle manufacturing plant in the world, annually capable of producing 550,000 vehicles and more than 600,000 engines.

Toyota Motor Manufacturing, Kentucky, Inc

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As well as positioning quality control member(s) at the seat arrival station before seats enter the facility.

Pros
Follows Toyota's philosophy
Stops problems before entering facility
Prevents problem from leaving KFS
Eliminates cost to fix and return
Involves Toyota more with manufacturer
KFS is geographically close to TMM ensuring effective pull system
Eliminates stopping the line
Keeps work flow steady
Majority of seat problems come from the manufacturer
Not necessarily long-term commitment
Cons
Costly to create and maintain new quality control positions
KFS could feel invaded and lack of trust
Time consuming
KFS could refuse to cooperate
SWOT
Alternative 2
Maintain an on-site supply of safety stock for when unexpected problems arise.
Pros
Resources available on site to reduce time wasted
Enables smoother flow of goods in the production process
Reduced disruption time
Short- term fix
Cons
Contradicts TPS goal to eliminate waste
Contradicts the concept of lean and JIT
High cost of storing and maintaining stock
Not a long-term fix
Demanding of space
Could backfire in terms of time as seat needs to be physically matched to car
Too many variations of seats, which would demand more storage space
Alternative 3
Employ a different seat manufacturing company who can keep up with multiple seat varieties and has a low rate of manufacturing defects
Pros
Could reduce number of issues with seats
Could keep a more efficient production line
Possibility to find a less expensive or better quality manufacturer
majority of problems came from the seat manufactures end
Expensive to implement change
Lose existing relationship with KFS
Establish a new relationship and trust
Potentially regret decision to switch manufacturer
Potentially unable to find reasonable price or quality
KFS is geographically close to TMM, current pull system effective
Higher cost of implementing pull system from further location
Cons
Alternative 4
Reduce the number of seat variations offered
Pros
Increase chance of a non-defective seat being available
Lowers the demand on KFS
Not as many problems until TMM increased demand of seat variety
Cons
Short-term fix
"Better cars for more people"
Contradicting position of meet diverse customer preference
Restricts availability to change in future
Less variety for consumers
Eliminates expansion of product development
Recommendations
Alternative 1

Involve TMM quality control with Kentucky Framed Seats (KFS)by going to KFS to identify the source of the problem and correct it on site.

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TOYOTA MOTOR MANUFACTURING ALABAMA, INC

Hino Motors Manufacturing, U.S.A., Inc. is a wholly-owned subsidiary of Hino Motors, Ltd. (Japan) and a Toyota Group Company. For four decades, Hino Motors, Ltd. has proudly manufactured the number one selling medium and heavy-duty truck in Japan. It also manufactures buses and diesel engines, Toyota's FJ Cruiser and Land Cruiser Prado.

Toyota Motor Manufacturing, U.S.A., Inc. - Harvard …

Since 1988, over 11 million vehicles have rolled off Toyota’s assembly lines in Georgetown, where full-time employment is more than 8,000. In addition to the Camry, America’s best-selling car, TMMK manufactures the Camry Hybrid, Avalon, Avalon Hybrid and Lexus ES 350, as well as four-cylinder and V-6 engines.

Toyota Motor Manufacturing, Alabama, Inc. (TMMAL)