1. How is buying an Auris Car like buying Nike Trainers?

2. Lesson Objectives
Analyse Business Stock Control situations and identify key advantages and disadvantages of Just in Time (Lean Manufacturing) at Toyota (Grade C+/B) Evaluate the advantages/disadvantages of stock control and highlight problems in the Supply Chain for global businesses. (Grade A/B)

3. Auris Toyota Car Production Burnaston, Derby
Press Shop Line

4. Toyota Factory at Burnaston, Derby on A38 and A50 Junction

5. Auris Built at Burnaston Derby
Auris built at Burnaston, customers in Europe
Auris Built at Burnaston Derby

6.  Koito Manufacturing light manufacturer in Japan
Headlights from Japan

7. Engines Built at Deeside, North Wales
Engine built at Deeside, North Wales
Engines Built at Deeside, North Wales

8. Auris Seats – Johnson Controls in Burton on Trent

9. Michelin Tyres made at Dundee, UK
Michellin 15in and 17 in alloys Wheels and tyres Michelin low-rolling-resistance tyres.

10. Steel Coil Warehouse in USA
Toyota Tsusho Group
Steel Coil Warehouse in USA
Burnaston uses 6.5 of these coils every day weighing 300 Tonnes of Steel.

11. Futaba Dove Valley Foston
Futaba Dove Valley Foston Derbyshire
Futaba Dove Valley Foston
Derbyshire

12. Toyota Inchcape Car Showroom Derby

13. Fuel Tank Made in Japan

14. Steering Wheels from France

15. Radio and Air Conditioner Units made in Japan

17. Lean Manufacturing using Just in Time
Supply Chain from Raw Materials to Finished Car
Lean Manufacturing using Just in Time
JIT is where raw materials and components, parts etc arrive at the factory JIT for assembly usually within a 2 hour window of being needed on the assembly line.
Toyota Factory at Burnaston, Derby on A38 and A50 Junction
Two Models of Cars
Avensis sold all over the world including Japan & Auris sold in Europe
Each Car is Made for a Customer’s Order
750 Cars manufactured a day 1 car every 66 seconds
260 parts from UK & 500 European Suppliers

18. In Groups
15 mins
Look at the information and scenarios to determine the advantages and disadvantages of Just in Time Production on Toyota and the concept of holding Buffer Stocks in the Supply Chain. For each Scenario make notes on the positives/negative impacts on Toyota

19. Positives + Minuses - & Interesting I
Everyone complete a PMI sheet on the Positives (advantages) of using Just in Time, different scenarios etc for Toyota Minuses (disadvantages) or concerns from external factors, or changes etc for Toyota Interesting – “It depends” concepts from issues raised in your discussions, or any other information you think Toyota might need to made decisions on Stock Control.

20. Scenario 1
Earthquake and Tsunami in Japan 2011 Natural Disaster Toyota Part Factory Destroyed Effects on Orders, Profits, Sales, Employees ………..

21. Scenario 2
ICELAND VOLCANO ASH CLOUD DELAYS ALL FLIGHTS IN EUROPE

22. Scenario 3
Economic Down turn continues throughout UK and Europe

23. Scenario 4
CHINA FOOD SHORTAGES CAUSES FACTORY WORKERS TO RETURN TO AGRICULTURE

24. Scenario 5
ICY WEATHER BRINGS UK TO A STANDSTILL

25. Scenario 6
TOYOTA CONSIDER INVESTING IN A WAREHOUSE FOR BUFFER STOCKS Costs, Employees, Benefits, What ifs?

26. Scenario 7
TOYOTA RECALL 800,000 CARS WITH FAULTY AIRBAGS

27. Scenario 8
MICHELIN TYRE MANUFACTURES DESIGN A NEW LOW EMMISSION TYRE FOR AURIS CARS (Scientific Research)

28. Scenario 9
Research & Development at Toyota introduce new colour ranges for Auris cars for paint, interiors and seats.