WINDSHIELD ROBOT PROJECT: A TOYOTA PLANT

REHABILITATION
I. BACKGROUND
Toyota Motor Philippines Corporation
> Business facility that is involved in Vehicle Assembly,
Vehicle and Spare Parts Sales, and Automotive
Dealership
> Manufactures all Innova and Vios cars in the
Philippines
Windshield and Backdoor Glass
> A framed pane of usually curved glass or other
transparent shielding located in front of the
occupants of a vehicle to protect them from the wind
> A shield placed to protect an object from the wind
Urethane Sealer
> This is a material used in fixing windshield
and backdoor glass onto the main body
> Dispensed by nozzle gun and MANUALLY
applied to the window glasses
Glass Preparation Process
> located at the 1st station in Final Line (LH & RH)
> 3 Manpower
> 2-shift operation
Windshield Sealer Equipment
> operating since 1995
II.PROBLEM
1. Increasing number of warranty claims regarding leaks on
windshield and backdoor glasses due to inconsistent
application of sealer
2. High consumption of sealer per unit
3. Aging equipment and obsolete parts





















III. OBJECTIVES
1. To ensure quality of sealer application
2. To eliminate customer claims regarding leaks
3. To lessen man-hour requirement in the process
4. To reduce cost expenses








IV. RESULTS AND DISCUSSION
A. CONDITION
Manual Application of Sealant





B. LAYOUT
PLANNING














Drop Lifter
Area
New Urethane
Sealer Equipment
Robot Area
Old Urethane
Sealer Equipment
Workstation
1
2 3
4
5
8
9
1
0
1
1
1
2
Temporary
(Back-up)

Fig 1. Products Manufactured by TMP


Fig 2. Some of the Products of TMP









CURRENT CONDITION
C. POSSIBLE SOLUTIONS





OPTION 1





OPTION 2




OPTION 3
V. CONCLUSION


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Due to increasing number of warranty claims regarding leaks on
windshield, it is recommended to shift sealer application from
manual to robot application (Option 2). Also, it is expected to
lower down sealer consumption per unit since robot will
standardize application of sealant onto the glasses. Shower Leak
Test will no longer be performed once the quality of sealer
application is achieved. This will require 1 year monitoring of
performance and expected to have no occurrence of glass leaks.
This proposal is a result of benchmarking in TMC. It will incur a
total cost of only Php 895,189.29 per year or more than Php 12M
savings.
Bonnie, more or less, ganito yung layout na gusto naming lumabas pag naprint na sa 30 x 40 na tarp.
Yung content sa mga boxes na empty, copiable na sya ditto sa word document na to, i-browse mo na
lang. thanks.