Origin of the Adoption of the Toyota Production System in China

Chunli Lee

doi:10.5029/jrbh1984.14.89

Chunli Lee

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ジャーナルフリー

1998 年 14 巻 p. 89-114

DOI https://doi.org/10.5029/jrbh1984.14.89

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Published: 1998/03/15 Received: - Available on J-STAGE: 2010/06/28 Accepted: - Advance online publication: - Revised: -
訂正情報
訂正日: 2010/06/28 訂正理由: - 訂正箇所: 引用文献情報訂正内容: Right : 1For more on the,formation and evolution of production systems,see Takahiro Fujimoto,“Iwayuru Toyotateki jiclosha kaihatsu/seisan shisutemu no kyoso noryoku to sono shinka-Kega no komyo to jigoteki gorisei”[The competitive capability of the so-called Toyota-style automobile development and production systems,and their evolution:“Flukes” and ex post facto rationality],parts1&2,Keizaigaku ronshu61,nos.2&3,1995;and H.Shiomi and K.Wada,eds.,Fordism Transformed:The Development of Production Methods in the Automobile Industry(Oxford University Press,1995).
2“Lean production system”is a term proposed by the Massachusetts Institute of Technology/International Motor Vehicle Program(IMVP).Basically it is an idealized form of the Toyota production system.For more details,see J.Womack,D.Roos,and D.Jones,The Machine That Changed the World(New York:Rawson Associates,1990).
3The work by Womack et al.and one by Tetsuo Abo et al.,Amerika ni ikiru Nihonteki seisan shisutemu[The Japanese-style production system alive in America](Tokyo:Toyo Keizai Shinposha,1991)are examples of the coverage given to other countries.For the few works on China's automobile industry,see Toshio Tajima,“Chugoku jidosha sangyo no tenkai to sangyo soshiki”[The development of China's automobile industry and industrial organization], Shakaikagaku kenkyu42,no.5,1991;Guowuyuan Jingji Jishu Shehui Fazhan Yanjiu Zhongxin[The State Council Research Center for Economic,Technological,and Social Development],eds.,Yiqi zai gaige kaifang shiqi de jishu gaizao-laizi shengchan diyixian de diaocha baogao[Technological innovation at FAW in the period of reform and openness:Report from the front line of production](Beijing:Zhongguo Caizheng Jingji Chubanshe[Chinese Public Financial Economy Press],1988;and Chunli Lee,Gendai Chugoku no jidosha sangyo-kigyo shisutemu no shinka to keiei senryaku[The Chinese automobile industry:Manufacturing system and technological strategy](Tokyo:Shinzansha,1997).
4The research for this study was based primarily on field surveys.I have visited FAW three times to conduct surveys there on17-19February1992,5-7September1994,and21-24December1994(including an interview with Professor Takahiro Fujimoto,University of Tokyo).I have also conducted surveys of Toyota five times(January1991,August1992,November1994and1996,July1997)and of Hino one time(February1996).
5For material on FAW's acceptance of and changes to the Ford system see Chunli Lee,“Adoption of the Ford System and Evolution of the Production System in the Chinese Automobile Industry,1953-93,”in Shiomi and Wada,eds.,Fordism Transformed,and Chunli Lee,“Chugoku jidosha sangyo ni okeru kigyo shisutemu no keisei to shinka ni kansuru kenkyu”[Formation and evolution of the enterprise system in the Chinese automobile industry](unpublished Ph.D.dissertation,Division of Economics,Graduate School of the University of Tokyo,1996).
6In regard to the expansion of FAW's business organization from the late1980s on,see Lee,op.cit.in Fordism Transformed.Figure1was compiled by the author from FAW publicity materials and Quiche Gongye Jiben Qinkuang1991[Basic state of the automobile industry,1991],vol.2,pp.124-125.
7Taiichi Ono,Toyota seisan hoshiki[The Toyota production system](Tokyo:Daiyamondosha,1978),p.199.
8Zhiguo Li,Jingyi shengchan fangshi yu qiye jingji xiaoyi[Lean production system and its economic performance](Beijing:Beijing Kexue Jishu Chubanshe[Beijing Science and Technology Press],1994),p.239,the bibliography.
9The work cited in the preceding note by Zhiguo Li,vice president in charge of production,contains the first publication of notes taken during Ono's lectures at FAW over ten years earlier.Unless noted otherwise,the material that follows is based on this work by Li and on an interview I had with Li on6September1994.I would note in passing that Li was the person responsible for inviting Ono to FAW in1981.
10FAW Department of Production Management,“Fengtian Qiche Gongsi daibiaotuan lai Yiqi fangwen qingkuang de huibao”[Report on the visit to FAW of the Toyota Motor Company delegation],appendix3in Zhiguo Li's work,p.232.
11Ibid.,pp.233-34.
12Ibid.,pp.234-36.
13This is based on pp.52-55of Zhiguo Li's work cited above and an article by Kimitoshi Sato,“Xianchang shiyandian zongje baogao”[Complete report on workplace testings],on pp.214-18of the same work by Li.
14The formula for calculating takt time is to divide the total amount of working time per day by the number of vehicles per day needed to fill orders.
15See Yiqi Biansuxiang-Chang[FAW transmission plant],“Tuixing zhunshihua shengchan fangshi,shizian qiye guanli zhengti yuhua-zai Yiqi Bansuxiang-Chang zhunshihua shengchan fangshi xianchang jingyian jiaoliu hui shang de huibao”[Promoting just-in-time production to achieve optimal management:A report presented for a worksite symposium at the FAW transmission plant on just-in-time production],Yiqi Gongzuo Qingkuang[FAW Review],No.5,1992,p.38.
16See Zhiguo Li,Lean Production System,p.241.
17Shaoye Geng,“Yiqi tuixing jingyi shengchan fangshi de shijian he renshi”[FAW implementation of,and lessons from,promoting lean production],in Quanguo Jijie Gongye Qiye Guanli Gongzuo Huiyi jingyian cailiao[Proceedings of the National Machine Industries Conference on Management Practices](1995),p.49.
18“Promoting Just-in-time Production to Achieve Optimal Management,”p.38.
19Zhiguo Li,Lean Production System,p.165.
20The materials I present in this section are based on interviews I conducted on6and7September1994and on the results of an inspection tour of the transmission plant.
21Zhiguo Li,Lean Production System,pp.171-72.
22This is according to notes I took when I visited the plant on7September1994.The terms that appear in the description of the quality control method will shortly be explained in the text.
23Unless I indicate otherwise,this account of production management and quality control is based on “Promoting Just-in-time Production to Achieve Optimal Management,”pp.39-42.Note that the inspection criteria and standard points for the preliminary line are not known.The Table is based on notes taken by the author during an inspection tour of the transmission plant on7September1994.
24“Xiang chuantong de daliang shengchan guanli moshi tiaozhan:Yiqi quanmian tuixing jingyi shengchan fangshi”[Challenging the conventional mass-production system:FAW promotes lean production system companywide],Renmin Ribao,29May1994.
25Unless otherwise indicated,the account given in this subsection is based on“Promoting Just-in-time Production to Achieve Optimal Management,”pp.45-46.
26Ibid.,p.45.
27Li Li Song,“Chugoku Daiichi Jidosha no moderu chenji ni okeru gijutsu donyu oyobi sono kyushu shoka purosesu ni tsuite no kosatsu-Hino Jidosha to no transmission gijutsu teikei o chushin ni”[Study on the introduction of transmission technology in FAW's model changes and of the process of absorbing and digesting that technology].Master's thesis,General Culture Division,University of Tokyo,1990,p.42.
28Ibid.,p.48.
29Based on interviews I conducted on7September1994.So is the next paragraph.
30Song's master thesis,p.48.
31It is probably appropriate to consider this“post wage”(a term coined by China's Department of Labor and Personnel)a form of position-linked pay peculiar to China.For more details,see Yo Nakanishi and Xin Geng,“Chugoku Daini Kisha Seizo-Sho‘Daini Jidosha kojo’no‘koshi meisai hyo’-‘kyuryobukuro’no kokusai hikaku,sono7”[Itemized account of salaries,Second Automotive Works of China:An international comparison of pay envelopes,part 7],Discussion Paper91-J-14,Faculty of Economics,University of Tokyo,1991.
32Shaojie Geng,“FAW Implementation of,and Lessons from,Promoting Lean Production,”p.54.
33“Promoting Just-in-time Production to Achieve Optimal Management,”p.31.Afterwards FAW learned cost management methods from Hino and set up a cost management department.
34“Challenging the Conventional Mass-Production System,”29May1994.
35Shaojie Geng,“FAW Implementation of,and Lessons from,Promoting Lean Production,”p.55

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