RAC Berth:Know the Company: Toyota: Toyota was established in Japan in 1937 and its first overseas production began in 1959 in Brazil. Expansion continued throughout the 1950s and 1970s with the spending of several overseas plants in Africa, South America, South East Asia and Australia. In 1985, a joint venture company was established in the USA and its own vehicle plants were established in the USA and Canada (in 1988). Toyota (UK) was established in 1989. Production in the UK plant started in 1992; current production is 100,000 units of vehicle with an investment of Pounds 700 million. The engine plant has investment of Pounds 140 million or with the current production of 100,000 units of engine. The target production capacity was recently raised to 200,000 units of vehicle with a further investment of Pounds 200 million. It is a relatively new plant. Production and operation system Toyota UKs aim is to satisfy the customer by providing the highest quality at lowest possible cost in a timely manner with the shortest possible lead times. It has a complete manufacturing operation including press and weld, paint, plastics, assembly and engine plus a comprehensive environmental control facility. Quality is built in at every stage and confirmed throughout the process. In the press and welding section coils of steel are pressed out into blanks, flat sheet shaped into the basic part in a pattern which minimises waste steel. Operating to just-in-time production, blanks are cut as required by the press lines. When the press lines require parts to be sent forward, order-details are entered on computers to ensure timely transfer by automatic guidance vehicle (ABV) to the press machines, the largest of which is capable of exerting a pressure of 4,000 tonnes. The presses give each part its third dimension using dies. Dies can be changed very quickly so stocks are kept to a minimum according to the Toyota production system, saving time, money and space. We have to remember that the so-called Japanese style production-inventory systems, which include just-in-time production, kanban system, total quality management, cell-based layout designs, were all invented in Toyota plants in Japan during the early 1950s. The completed body panels are welded together (90 per cent done by robots) into larger main sub-assemblies. These sub-assemblies are then brought together by robot to form a complete body shell. Throughout the process, team members and technology work together to build a high quality vehicle. At each stage, the team members check the quality of the work before passing the vehicle on while a number of automated intelligent systems interact to instruct and control the car building system. The car then needs to go through painting, plastic moulding of instrument panels and engine assembly. Despite around 2,500 parts having to be fitted to each car, there are only two temporary parts storage areas where a maximum of eight hours stock is held. A manifest (printed document) is fitted to the car, containing details of its specifications and providing visual control throughout the assembly process. The car then travels down the assembly line. Throughout the process, each member is responsible for the quality of work they produce and pass on, so an audio cord adjacent to the line enables each member to stop the production line if they have a concern. The cord is pulled once to call support from the team leader; in many cases the problem is addressed quickly, the cord is pulled again by the team leader and the line continues never having stopped. If the problem is a little more serious, the team leader will allow the line to stop until the concern is resolved. Although quality is built in at every stage a complete functional and visual inspection is carried out before line-off to ensure complete customer satisfaction.
Posted on: Sat, 24 Jan 2015 04:48:31 +0000
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