“We deeply regret the inconvenience and concern caused to our customers and others by our recent recalls of multiple vehicle models across multiple regions.” – Aki Toyoda, the CEO of Toyota Motor Corporation1 (Toyota website). Beside the regretful expression we can learn from this public release, it also implies that Toyota, one of the world’s largest automakers, is suffering in their recent recalls of millions of vehicles round the world. Safety recalls are common issues occurring in the automobile industry, few may have long run impact on the automakers involved if handled correctly. However, in this case, the disaster engulfing Toyota is of a different order (The Economist, Feb.6, 2010). Toyota’s quality brand has been scrutinised and at risk due to its sedans’ safety problems that have sequentially emerged recently.…
Processes need to be constantly analyzed in order to see if they are operating at full potential. The Toyota Production System (TPS) is one of the most effective processes in the world but it was not fully integrated into foreign market plants. Following is a refined problem statement elaborating on the prior one: The TPS process is not fully in place in all plants across all markets. A fishbone diagram and a flowchart have been provided in order to get to the root of the problem and develop a process improvement plan as well as a complimenting scope. In order for Toyota to remain successful and be prevalent well into the future, the TPS rollout process must be completed smoothly and full-heartedly into all foreign markets.…
An automobile accident involving a Lexus (subsidiary of Toyota) vehicle resulted in the deaths of four people in California on August 28, 2009. Mark Saylor took his car into the Bob Baker Lexus dealer in El Cajon, CA to have it serviced and they provided him a loaner 2009 Lexus. While Saylor was driving the Lexus loaner it suddenly accelerated and he couldn’t control the car. One of the three other occupants in the car called the police on their cell phone to report that the car’s accelerator was stuck. The Lexus rear ended another vehicle before going down an embankment and bursting into flames at the bottom of the San Diego River killing everyone inside the car. According…
Toyota used to sit on top of the world. It basked in the reputation of building high-quality cars efficiently. It enjoyed unprecedented growth, even surpassing General Motors as the largest car manufacturer in the world. But all of that came tumbling down with reports that cars were accelerating out of control, careening down highways, and putting everyone’s lives in danger. There was even a recording of a 911 call from an off-duty policeman who lost control of his car and died in the ensuing crash. Toyota responded with a recall of historic proportions—nearly 8 million cars in the United States and 1.8 million in Europe. It even suspended sales of brand new models, including the best-selling Camry and Corolla, until the vehicles could be repaired. But still, there was confusion about what was causing the problems—was it the floor mats, the braking system, the software controlling the engine, or something else? Conspiracy theorists argued that Toyota had no clue what was causing the sudden acceleration and that their recall was basically worthless.…
On September 29, 2009, Toyota recalled 3.8 million U.S. vehicles, and on January 16, 2010, another 2.3 million more were recalled for what was determined years after the initial complaint of a “stuck accelerator pedals.” (Greto, 2010) After Toyota’s executives were called to congress and forced to stop selling their cars, the U.S. fined Toyota with a 16.4 million dollar civil penalty. In addition, Toyota Motor Corp., in December 2012, agreed to pay $1.1 billion to settle a class-action lawsuit stemming from complaints of unintended acceleration in its vehicles that soured its reputation for quality and undermined its sales globally. (Ramsey, 2012) Three processes were identified within Toyota that will benefit from improvement: 1) Leadership, 2) Quality Management, and 3) Communication.…
Toyota originally blamed floor mats for the recall even though the gas pedal was the actual cause, but the car owners need to know exactly what was causing the gas pedal to accelerate and stick, without releasing. In conclusion that Toyota has a problem producing defective gas pedals, the following are examples: October 25, 2009 LA Times reported, “A federal report finds a possible flaw in the gas pedal design of a runway Lexus that crashed in August, killing CHP officer Mark Saylor and three family members and leading to a massive recall.” Resulting in Toyota’s first recall due to defective gas pedals because on January 21st, the number one car company recalled two point three million vehicles and the underlying problem was a “sticky pedal” which did not properly release. The company announced that it would halt sales and production, including some of its top selling models with the gas pedal problem, and fix the defect that caused the pedals to stick. Therefore unintended acceleration would not happen again, due to the pedal. The emphasis is about fixing customer cars and placing sales on the back burner, yet Toyota waited twelve days to come up with a solution. Jim Lentz spoke on February 1st, 2010 saying, “Dealers priority should be on repairing customers’ vehicles rather than fixing vehicles for sale on the lot.” The phrase “actions speak louder than words” is true we don’t just want to hear talk, but an approach to take charge or action. In terms of time one would expect something to be done as soon as possible. Especially when it comes to safety, steps have been taken that shows at least they recognized the problem and came up with a solution.…
Toyota abandoned its mantra of quality, and aggressively seek market share. Toyota expended rapidly in order to become the top global manufacturer, but its quality began to decline and also leading to its reputation beginning to slip. Toyota developed a pattern of slow reactions and secrecy in regards to safety concerns and defects in its vehicles. When definitive causes were found, their marketing team should have publicized the investigation to show that the company was listening to consumers and in complete control of the situation. Lentz said Toyota 's recall crisis taught the automaker need to be "much more transparent, both inside and outside the company." "You have to be able to listen to your customers, not just hear them, but listen to what they 're telling you -- and be quick about it." (Rechtin, 2014)…
As of January 28, 2010 9 million Toyota’s were recalled worldwide due to an issue with the pedal entrapment/floor mat problem.There were allegations about what the problem was some people said it was the floor mats that could easily get stuck on the pedal and cause unwanted acceleration. Others claimed that there was a problem with the accelerator itself. On February 8, 2011 the National Highway Traffic Safety Administration (NHTSA) in participation with NASA performed an investigation on the throttle system of the Toyota vehicles. The study lasted for 10 months and afterwards the scientist from NASA and NHTSA announced they found no defect. Sometimes mistakes like this can be crippling to a company’s reputation. In business it is important to have a plan for everything. All business should have a thorough business plan if they want to be successful, and Toyota has a very thorough business plan. As a CEO I would write out a detailed plan on how our company would overcome this obstacle and follow that plan precisely, this plan would consist of all the steps our company will take during the initial stages of rebuilding our brand. It’s important to maintain a good public image for the company. A bad public perception of a company can be fatal. The plan that I have will include the following steps: 1) Stop the production until the problem is fixed. 2) Apologize and explain what happened. 3) Explain the corrective actions we would take and what we’re doing to do to prevent this in the future. 4) Advertise/Rebuild the brand.…
There were several advantages of Toyota’s manufacturing system when compared with conventional manufacturing system. Ohno Taiichi was the person responsible in helping Toyota shift from the established method of manufacturing automobiles set by Ford. The basic philosophy was to produce everything in mass quantity to gain maximum economies of scale. The logic was to spread the fixed cost over the production line and benefit from lower cost. Another characteristic of this philosophy was to make each worker perform a single task only. This premise was supported by the fact that if one worker performs the same task over and over again then eventually he or she would get faster in doing so. Ohno Taiichi was able to identify several flaws in this philosophy. Firstly, mass production of same item meant that what was not used had to be stored in warehouses. This resulted in high storage cost. At the same time it tied up inventory in unproductive uses. Secondly, if anything goes wrong in initial machine setting, that would mean massive production of defective parts. Thirdly, if each worker is assigned to do only one task then that resulted in quality mismanagement. Fourthly, this philosophy created the problem of employing specialist at extreme ends of division of labor. There were many tasks that could have been performed by one person. Lastly, mass production system created hindrances in making customizable products.…
Toyota believes in order to maintain its highest level of quality; their vehicles should be produced where the demand exists with the same level of quality no matter where the manufacturing plant is located. Among the hurdles that must be…
Toyota weathered through a lot of problems over the years from the accelerating recall to the engine oil sludge, but found their way to sustain and grow. Mr. Toyoda had to sort out what combination of structural, cultural, or strategic challenges led to the current recall crisis. Clearly, Mr. Toyoda had much to do to fix the problems of the recent past, and restore confidence in his company and the brand moving forward. More…
The Ford Pinto case study clearly presents an unethical and immoral practice that shows corporate greed for a positive bottom line is more important than the value of human life. Along with the issue of greed is the need to outdo the competition to be the best in the automobile industry. Together these issues cloud the judgment of Ford’s management. The use of cost-benefit analysis to determine if the flaw in Ford Pinto automobiles is worth the financial risk in comparison to the value of human life is unconscionable and indefensible. Because of this cost-benefit analysis, Ford made a costly decision not only in terms of money but also human life, pain and suffering for victims and their families, and to its own reputation. Ford chose to pay for possible lawsuits in lieu of recalling and repairing the Ford Pinto. Many deaths and catastrophic injuries were the result of Ford’s unethical decision that resulted in dozens of lawsuits and also led to the three reckless homicide indictments against Ford Motor Company. If Ford had the right business ethic and moral integrity to put consumer safety first, instead of profit and competition, there would have been no loss of life or financial suffering because there would not have been lawsuits.…
“Since Jan. 27, NHTSA has received complaints of 13 more deaths and 10 injuries in U.S. crashes, since 2005, that allege sudden acceleration as the cause in Toyota vehicles,” chronicles the Detroit News. “That brings to 34 the total number of deaths since 2000 allegedly related to unintended acceleration in Toyotas.” “In addition to the fatalities, federal regulators said 22 people reported injuries from unintended…
3) Where if at all, does the current routine for handling defective seats deviate from the principles of the Toyota Production Systems?…
I fear the pace at which we have grown may have been too quick. I would like to…