Toyota Motor Manufacturing Indiana Stamping Plant Tour

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Toyota Motor Manufacturing Indiana Stamping Plant
Tour

• August 23, 2001
• Princeton, Indiana

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Toyota Motor Manufacturing

• Attendees
• Toyota Motor Sales Guests
• Roger Foss Sheila Loftus
• Karl Krug Karen Fierst
• Randy Profeta Chuck Sulkala
• Rod Enlow
• Lou DiLisio
• Unable to attend due to flight issues
• Kelly Roe, Don Feeley

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Toyota Motor Manufacturing

• Agenda
• Wednesday August 22, 2001
• Group Dinner
• Thursday August 23, 2001
• Toyota Production System Review
• Tour Of Stamping and Assembly Plant
• Toyota Collision Industry Presentation
• Group Lunch

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Toyota Motor Manufacturing

• Toyota Production System
• Eliminate Waste
• Raise Efficiency
• Increased Quality

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Toyota Motor Manufacturing

• Toyota Production System Key Elements
• Establishing Work Teams
• Next Process Is Customer for Previous
• Small Lot Production (Kanban)
• Kaizen
• Do it once right!

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Toyota Motor Manufacturing

• Toyota Production System Key Elements
• Establishing Work Teams
• Keep Employees Involved
• Incorporate Employees and suggestions in the
  process
• Cross Train employees in multiple tasks

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Toyota Motor Manufacturing

• Toyota Production System Key Elements
• Next Process Is Customer for Previous
• Relational Dependency
• Constantly monitors potential issues and areas
  for improvement
• Quality Control step by step

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Toyota Motor Manufacturing

• Toyota Production System Key Elements
• Small Lot Production (Kanban)
• KANBAN Just in Time Production
• No costly inventory
• Parts available as needed
• Identify issues / areas needing improvement in
  small batches Quality Control Measure

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Toyota Motor Manufacturing

• Toyota Production System Key Elements
• Kaizen
• Constant Improvement
• Any process can be constantly improved
• Toyota System is constantly changed and improved
• Make better vehicle more efficiently

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Toyota Motor Manufacturing

• Toyota Production System Key Elements
• Do it once right!
• Use high quality raw materials

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Toyota Motor Manufacturing

• Tour of the Plant
• Safety is of the utmost concern
• Steel is obtained from US sources.
• Metallurgical tests are done on each coil
• Lots of 50 500 parts are run at a time (1
  11/2 days production needs)
• Dies are inspected after each production run

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Toyota Motor Manufacturing

• Tour Of the Plant (cont.)
• Parts are developed from specifications, they are
  not reverse engineered
• The first and 100th part off the run are pulled
  for visible inspection
• Parts are QCd every 80 seconds
• Service and line parts are one in the same

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Toyota Motor Manufacturing

• Tour of the Plant (cont.)
• There are approximately 2700 welds on a Toyota
  Sequoia or Tundra and they are approximately 70
  automated
• Application of adhesives is done by robotics
• Maintenance is done on a daily schedule

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Toyota Motor Manufacturing

• Toyota Collision Industry Support
• Toyota provides technical training to the
  industry at large
• Training is available in self study programs as
  well
• Toyota produces numerous repair procedure and
  support manuals / information

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Toyota Motor Manufacturing

• Toyota Collision Industry Support
• Training course packages
• Body repair procedures
• Information bulletins
• Collision repair manuals
• Collision repair reference guides
• Call your local dealer
• E-mail collisionpros_at_toyota.com

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Toyota Motor Manufacturing

• Thank you
• Toyota Motor Sales
• and the
• O/E Roundtable
• for this opportunity