109:
production system worked, and that they had "the right balance of efficiency and risk". Toyota also learned to reduce the number of variations in its parts to make production easier as well as to reduce risk. Toyota's suppliers also had the benefit of increasing efficiency in their production as well
92:
Aisin, along with Toyota, set up a crisis room to deal with the problem of manufacturing new P-valves. Toyota managed to get many of its suppliers to bring in additional engineers, and work overtime shifts, to help build machines to produce P-valves, as well as increase production of the components.
117:
system, where businesses have "interlocking" relationships with each other. The loyalty shown by Toyota's suppliers to the company showed it the value of long-term business relationships: the suppliers reportedly did not ask what they would be paid for rushing out the valves; Aisin and Toyota later
83:
With the factory out of production, it was estimated that Toyota would have to halt car production for weeks. The economic impact of this would have been huge for Toyota, the local economy and for Japan. It was estimated that each day Toyota production was halted would lead to a 0.1% decrease in
96:
The first usable valves were delivered to Toyota on the
Wednesday (February 5) following the fire, allowing production of cars to resume. While observers initially predicted that Toyota would have to halt production for weeks, the incident ultimately set Toyota's production back only five days.
46:
However the event also provided an example of successful business relationships between Toyota and its suppliers, allowing the company to quickly manufacture replacement parts and limit the halt in production of its cars, thereby minimizing the losses from this event.
93:
Some of Toyota's suppliers, and their subcontractors, were persuaded to give priority to the production of P-valves. Even a sewing machine manufacturer was persuaded to help provide valves for Toyota.
80:
Co. producing the remaining 1%. The production of P-valves was complicated, and required specialised tools. Furthermore, different varieties of P-valves were in production.
118:
reimbursed them for the work, including the valves, overtime and re-tooling of their machines, as well as providing a $ 100 million bonus to the suppliers involved.
238:
73:(P-valves) which help prevent skidding by controlling the pressure on rear brakes, and are used in the braking system of all Toyota vehicles.
35:
on
February 1, 1997, a Saturday. The event was notable as the factory was the main supplier of a motor part for Toyota cars. Due to the
258:
263:
200:
105:
The fire and the subsequent production crisis held many lessons for Toyota. It showed them that their implementation of the
178:
248:
132:
40:
106:
36:
243:
70:
253:
113:
The efficiency with which production was re-established also showed the value of the
Japanese
127:
32:
55:
The fire started before dawn on
February 1, 1997, at Aisin Seiki Co.'s Factory No. 1 in
232:
212:
77:
67:
170:
110:
as learning the lessons of building redundancy into their production methods.
29:
43:, Toyota's car factories reportedly only kept four-hour stocks of the part.
114:
56:
25:
60:
21:
171:"How Toyota Recovered From A Major Fire in Less Than a Week"
199:
Toshihiro
Nishiguchi and Alexandre Beaudet (Fall 1998).
24:
which shut down one of the production facilities of the
76:
99% of Toyota's P-valves were made at this plant, with
63:. The cause of the fire was reportedly unknown.
8:
143:
201:"The Toyota Group and the Aisin Fire"
175:Mirror of Wall Street Journal article
165:
163:
161:
159:
157:
155:
153:
151:
149:
147:
7:
14:
181:from the original on 14 June 2006
39:stock keeping philosophy of the
239:Industrial fires and explosions
41:Toyota Production System (TPS)
1:
205:MIT Sloan Management Review
84:Japan's industrial output.
280:
211:(1): 49–59. Archived from
259:1997 industrial disasters
133:Toyota Production System
264:1997 disasters in Japan
101:Lessons from the fire
66:The factory produced
71:proportioning valves
249:1990s fires in Asia
271:
224:
223:
221:
220:
196:
190:
189:
187:
186:
167:
279:
278:
274:
273:
272:
270:
269:
268:
229:
228:
227:
218:
216:
198:
197:
193:
184:
182:
169:
168:
145:
141:
128:Aisin Seiki Co.
124:
103:
90:
53:
33:Aisin Seiki Co.
18:1997 Aisin fire
12:
11:
5:
277:
275:
267:
266:
261:
256:
251:
246:
241:
231:
230:
226:
225:
191:
177:. 1997-05-08.
142:
140:
137:
136:
135:
130:
123:
120:
102:
99:
89:
86:
52:
49:
13:
10:
9:
6:
4:
3:
2:
276:
265:
262:
260:
257:
255:
252:
250:
247:
245:
244:1997 in Japan
242:
240:
237:
236:
234:
215:on 2006-09-01
214:
210:
206:
202:
195:
192:
180:
176:
172:
166:
164:
162:
160:
158:
156:
154:
152:
150:
148:
144:
138:
134:
131:
129:
126:
125:
121:
119:
116:
111:
108:
100:
98:
94:
87:
85:
81:
79:
74:
72:
69:
64:
62:
58:
50:
48:
44:
42:
38:
34:
31:
27:
23:
19:
217:. Retrieved
213:the original
208:
204:
194:
183:. Retrieved
174:
112:
107:Just In Time
104:
95:
91:
82:
78:Nissin Kogyo
75:
65:
54:
45:
37:just in time
17:
15:
68:brake fluid
254:1997 fires
233:Categories
219:2006-06-19
185:2006-06-19
139:References
30:subsidiary
179:Archived
122:See also
115:keiretsu
88:Recovery
51:The fire
57:Kariya
26:Toyota
20:was a
61:Japan
22:fire
16:The
235::
209:40
207:.
203:.
173:.
146:^
59:,
222:.
188:.
28:-
Text is available under the Creative Commons Attribution-ShareAlike License. Additional terms may apply.