|Toyota Production Systems Laboratory|
The Toyota Production Systems Laboratory currently resides in a 2500 sq. ft. facility in the Kate Gleason College of Engineering. It contains two modular assembly lines and a warehouse, as well as a storage area that contains parts, assemblies, and structural components. Founded in 2006 with support from the Toyota Motor Engineering & Manufacturing North America, the mission of this facility is to provide hands-on education in state-of-the-art production systems. Particular emphasis is placed on the concepts of teamwork, problem solving, and process improvement by studying the fundamental behavior of production lines.
The Toyota Production Systems Laboratory allows for the study of the following elements of production:
• Production Line:
Line balancing, workstation design, self‐balancing lines (“bucket brigades”), job location and cycle time, throughput, WIP accumulation, queue size per station, idle time, and station utilization.
• Receiving Functions:
Order receipts, receipt validation, identification of shortages and overages, transaction moves, printing of license plate labels, and printing of bin labels.
• Pick‐and‐Pass Area for Put‐away & Picking:
Virtual interface between receiving and flow through P‐T‐L area, put‐away function with pick‐to‐light, barcode and directed manual operation, acknowledgement of directed picking and validation of operation against orders, zone scheme flexibility for 1, 2, 3 and 4 zones based on 120 light location mapping, manual slotting of SKUs to rack, stocking replenishment, exception reporting by zone and picker, data storage in Excel spreadsheet for display of picker productivity, picks per unit time, pick density, and accuracy.
• Shipping Functions:
Manual packing, printing of shipping labels, printing of shipping documents (bill of lading, common carrier, 3rd party shipping manifests, etc.), and downloading of WMS data into Excel spreadsheet.
• Kitting Stations:
Build‐to‐Light capabilities with automotive parts/kits, configuration for two station with 15‐lights each, and data storage in Excel spreadsheet for display and reporting.
In addition to white boards and “A3” poster display areas throughout the facility, the Toyota Production Systems Laboratory also houses the following equipment, listed below:
For assistance or more information, please contact:
Andres L. Carrano, Ph.D., Lab Director
Phone: (585) 475-2598
John Kaemmerlen, Associate Lab Director
Phone: (585) 475-2767