ABSTRACT
This chapter defines the exact nature of the problem that Ohno had to solve in the age of increasing product variety. A solution to the problems is the robust process-flow architecture with even-pulse-generation, real-time transmission, and single-point control. The effect that product variety exerts on production depends heavily on the precise nature of the variety. Although flexibility is the regular focus of attention in the general discussion of product variety. The chapter provides the notion of product variety–a notion that normally conjures up the image of distinct models like the Toyota Corolla–and gives rise to a discussion of flexibility. It examines the problems presented by the intra-model product variety. The chapter also defines the basic intention of Ohno's solutions in a somewhat idealised world. It discusses the constraints of the real world and the compromises Toyota makes.
