Mura (斑) is a Japanese term for unevenness. It is also a key concept in the Toyota Production System and is one of the three types of waste (Muda, Mura, Muri) it identifies. Waste reduction is an effective way to increase profitability. The Toyota Production System (TPS) (トヨタ生産方式) is the philosophy which organizes manufacturing and logistics at Toyota, including the interaction with suppliers and customers. ... Muda (無駄) is a Japanese term for anything that is wasteful and doesnt add value. ...

Mura is avoided through Just-in-Time systems which are based on little or no inventory, by supplying the production process with the right part, at the right time, in the right amount, and first-in, first out component flow. Just-in-Time systems create a “pull system” in which each sub-process withdraws its needs from the preceding sub-processes, and ultimately from an outside supplier. When a preceding process does not receive a request or withdrawal it does not make more parts.

For example:

1. The Assembly line “makes a request to,” or “pulls from” the Paint Shop, which pulls from Body Weld.
2. The Body Weld Shop pulls from Stamping.
3. At the same time, requests are going out to suppliers for specific parts, for the vehicles that have been ordered by customers.
4. Small buffers accommodate minor fluctuations, yet allow continuous flow.

If parts or material defects are found in one process, the Just-in-Time systems force the problem to be quickly identified and corrected.

A Just-in-Time system delivers clear results:

• Quality is confirmed at every step, through first-in, first-out flow,
• Cost is reduced by eliminating the need for warehousing, as well as the expense of scrapping warehoused parts that are found to be defective. The need for extra labor costs is also eliminated.
• Maximum productivity is a result when the right parts and materials are supplied at the right time and in the right amount.

Implementation

Production levelling and frequent deliveries to customer are key to identifying and eliminating Mura. The use of different types of Kanban to control inventory at different stages in the process are key to ensuring that "pull" is happening between sub-processes. The use of Heijunka will aid in scheduling work in a standard way that encourages lower costs. Production levelling is key to reducing the Mura waste and to the development of production efficiency in the Toyota Production System and Lean Manufacturing. ... Kanban (in kanji 看板 also in katakana カンバン, where kan 看 カン means visual, and ban 板 バン means card or board) is a concept related to Lean or Just In Time (JIT) production, but these two concepts are not the same thing. ... Just In Time (JIT) is an inventory strategy implemented to improve the return on investment of a business by reducing in-process inventory and its associated costs. ...

It is also possible to smooth the workflow by having one operator work across several machines in a process rather then have different operators; in a sense merging several sub-processes under one operator. The fact that there is one operator will force a smoothness across the operations because the workpiece flows with the operator. There is no reason why the several operators cannot all work across these several machines following each other and carrying their workpiece with them^[1]. This multiple machine handling is called "multi-process handling" in the TPS. TPS may refer to: IATA code for Vincenzo Florio Airport Tall Poppy Syndrome Taxe de produits et services (Goods and Services Tax) Telephone Preference Service Télévision Par Satellite Temporary Protected Status Test Pilot School Test Procedure Specification The Pennington School The Petersfield School The Polyphonic Spree The Potter...

References

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