T O Y O T A @ W O R K Vol.

15
Introducing Toyotas Businesses Part IV Engine Division
This is the 4th installment in our series on Toyota business
divisions. The Engine Division develops and manufactures
diesel and gasoline engines from 1.5 to 4.7 liters. These
TO YOTA TE XTI LE MA CH IN ER Y
engines go into Toyota Motor Corporation passenger cars and

B U L L E T I N
Toyota Industries forklifts.

Based on its motto of Quality No. 1, the Engine

Division constantly strives to make high-power, fuel-
efficient, low-noise and low-vibration engines that are
Engine Division History constructed from recyclable materials and that thus
1953 Kyowa Plant begins manufacturing passenger car engines. achieve both environmental friendliness and superb
1982 Hekinan Plant goes on line manufacturing diesel engines efficiency. The Hekinan Plant, which started operation
for passenger cars. in 1982, boasts lines equipped with unmanned
1991 Engine production reaches 5 million. transport machinery and rest and relaxation facilities,
1998 Engine production reaches 8 million. giving employees an environment conducive to healthy,
2001 Engine production reaches 9 million. productive work.

Main Products

1CD-FTV 2,000 cc engine

for small passenger cars
A direct diesel-injection engine used in cars like
the Estima and Corolla in Japan, and in the
Avensis, RAV4, and Corolla in Europe.
2UZ-FE 4,700 cc engine for large RVs
Used in both the domestic and export versions of
all Land Cruiser models except the Prado. This
diesel engine is also used in the Coaster.
4Y 2,200 cc engine for industrial vehicles
Used in industrial vehicles like forklifts, and for
driving gas heat pumps and bus coolers.
2 Special Feature
JAT710s IT Functions

4 Technical News
Toyota Spun Sizer Pre-Wet Sizing System
About the Cover: Japanese DesignIn Style to Stay
The Western fashion world has witnessed a wave of Japonismthe love of things Japanesein 5 Whats New
2-1, Toyoda-cho, Kariya-shi, Aichi 448-8671, Japan recent years. No longer merely relegated to the realm of the kitsch, esoteric, and foreign, todays DX8 High-Speed Drawing Frame
Tel: 81-566-27-5326 Fax: 81-566-27-5307 Japanese fashion boasts patterns of intricate, graceful beauty and is equal in status to its Western
URL: http://www.toyota-industries.com/textile
counterpart. Visitors to Japan love to take home not only Japanese-patterned clothing but also
knick-knacks like hand mirrors and fans.
6 Customer Support & Service
E-mail: kaoru.kumamoto@mail.toyota-shokki.co.jp Electronic Parts Catalog
Tips from the Service Department
Please send your comments or questions regarding the TOYOTA TEXTILE MACHINERY
Toyota Textile Machinery Bulletin to any of the above addresses. BULLETIN Vol.15 7 Thoughts & Feelings
Contact person: Ms. Kaoru Kondo User Report Part 14:
Published July 2003
Shandong Weiqiao Textile Group Co., Ltd. (China)
Art direction and editorial assistance: Cs Inc. All rights reserved. Reproduction in whole or in part without written permission is
Printing: Okamura Printing Industries Co., Ltd. prohibited. This bulletin is printed on recycled paper.
8 Toyota @ Work
Introducing Toyotas Businesses
Part IV: Engine Division
Printed in Japan
8
 S P E C I A L F E A T U R E

TMS (Toyota Monitoring System)

Introducing the JAT710s IT Functions
The JAT710 Air Jet Loom boasts a powerful
CPU, a function panel with built-in Web
browser and the newly developed TMS
(Toyota Monitoring System)all of which
contribute to next-generation factory
management.
The JAT710s IT functions not only allow operators to
gather data from each loom with a PC (monitoring),
By connecting the JAT710 to a network with a standard LAN cable and installing Toyotas proprietary software, the
operator is able to monitor loom shift data and connect to networks both inside and outside the company. This system
also enables looms to exchange data with one anothera world-first. TMS can be used with the customers existing
PCs*, making it easy for them to introduce a high-performance network system into their mills. Consequently, many
JAT710 owners have already adopted TMS.
*PCs running Windows 2000/Windows XP
Monitoring Function

but also enable two-way communication between The operator can view data such as production volume,
looms and direct connection to networks inside and efficiency ratio and warp out forecast of each loom from a
outside the customers company. PC.
The data is displayed as a Microsoft Excel file for easy
editing and processing.
Shift report Stop analysis graph

JAT710 Network System

External Network Customer Internal Network Production graph Efficiency graph Warp out forecast

Customer Customer
Mobile PC head office sales division
Customer mobile PC Customer server Customer PC World Two-Way Communication between
First Looms

Two-way communication between looms, a feature not possible

Customer Customer
R&D division mill office with conventional monitoring systems, is now available for the
first time in the world.
Customer PC Customer PC Customer printer The operator can check data such as efficiency and production
Internet volume, as well as view and change the settings of a remote
loom from the function panel of another loom.
Loom settings can be copied onto different looms without the
use of memory cards.
Customer Mill Network

World Two-Way Communication with

First Internal/External Networks
JAT710
function panel Direct two-way communication with networks outside of the mill
Customer
textile mill is now possible for the first time in the world.
Communication with other divisions, such as sales and R&D
divisions, is now possible, which means the operator can view
mill data such as production volume and efficiency from a
remote location. The operator can also exchange information
with sales and R&D divisions from inside the mill.
The function panel screen displays a variety of information
Through an Internet connection, the operator can communicate
with various locations outside the mill using the JAT710s
function panel. This makes it possible to exchange information
with customers mobile PCs as well as exchange technical
information with Toyota. The contents of the function panel screen can be printed out,
Operators can directly view the function panel screen of a given allowing the operator to save loom settings for a variety of
Monitoring Instruction manual Technical information TICS Parts catalog Camera view loom from anywhere in the world to confirm loom settings. fabric types.

2 Note: Date of availability differs with each item. 3

 S P E C I A L F E A T U R E

TMS (Toyota Monitoring System)

Introducing the JAT710s IT Functions
The JAT710 Air Jet Loom boasts a powerful
CPU, a function panel with built-in Web
browser and the newly developed TMS
(Toyota Monitoring System)all of which
contribute to next-generation factory
management.
The JAT710s IT functions not only allow operators to
gather data from each loom with a PC (monitoring),
By connecting the JAT710 to a network with a standard LAN cable and installing Toyotas proprietary software, the
operator is able to monitor loom shift data and connect to networks both inside and outside the company. This system
also enables looms to exchange data with one anothera world-first. TMS can be used with the customers existing
PCs*, making it easy for them to introduce a high-performance network system into their mills. Consequently, many
JAT710 owners have already adopted TMS.
*PCs running Windows 2000/Windows XP
Monitoring Function

but also enable two-way communication between The operator can view data such as production volume,
looms and direct connection to networks inside and efficiency ratio and warp out forecast of each loom from a
outside the customers company. PC.
The data is displayed as a Microsoft Excel file for easy
editing and processing.
Shift report Stop analysis graph

JAT710 Network System

External Network Customer Internal Network Production graph Efficiency graph Warp out forecast

Customer Customer
Mobile PC head office sales division
Customer mobile PC Customer server Customer PC World Two-Way Communication between
First Looms

Two-way communication between looms, a feature not possible

Customer Customer
R&D division mill office with conventional monitoring systems, is now available for the
first time in the world.
Customer PC Customer PC Customer printer The operator can check data such as efficiency and production
Internet volume, as well as view and change the settings of a remote
loom from the function panel of another loom.
Loom settings can be copied onto different looms without the
use of memory cards.
Customer Mill Network

World Two-Way Communication with

First Internal/External Networks
JAT710
function panel Direct two-way communication with networks outside of the mill
Customer
textile mill is now possible for the first time in the world.
Communication with other divisions, such as sales and R&D
divisions, is now possible, which means the operator can view
mill data such as production volume and efficiency from a
remote location. The operator can also exchange information
with sales and R&D divisions from inside the mill.
The function panel screen displays a variety of information
Through an Internet connection, the operator can communicate
with various locations outside the mill using the JAT710s
function panel. This makes it possible to exchange information
with customers mobile PCs as well as exchange technical
information with Toyota. The contents of the function panel screen can be printed out,
Operators can directly view the function panel screen of a given allowing the operator to save loom settings for a variety of
Monitoring Instruction manual Technical information TICS Parts catalog Camera view loom from anywhere in the world to confirm loom settings. fabric types.

2 Note: Date of availability differs with each item. 3

 Technical News What's New

Toyota Spun Sizer

Pre-Wet Sizing System DX8 High-Speed Drawing Frame Debuts
The Toyota DX8 High-Speed Drawing Frame takes
Cuts Sizing Costs and Helps Keep the Environment Clean
quality, productivity and ease of use to even higher
What

is Pre-Wet Sizing? levels, precisely meeting diverse customer needs.
Pre-wet sizing involves passing the yarn through hot water and
Squeezing
squeezing out excess moisture before applying size. Running the
yarn through a preliminary hot water box removes cotton wax and
Sizing
Offers High Levels of Both Quality and
foreign matter, which allows the size to penetrate the yarn more Productivity

smoothly, and enables a thinner, more uniform size application. This Soaking in

makes it possible to cut size consumption, and also provides the

hot water Optimized sliver feed path
added benefit of reducing the amount of size that must be removed (feed, draft, coiling, etc.)
in the finishing process that would normally enter the industrial Hot water box Size box
Twist-free in-line sliver feed enables precise weight
waste stream, resulting in a cleaner environment. measurement.
Newly designed sliver guides provide optimal
sliver feed width.
Toyota Pre-Wet Sizing System Features Newly designed gatherer forms slivers with fleece wrapped
inside and with no fuzz.
SIZE-NAVI System
This system controls the size concentration in Calculation of
actual moisture content
Target size concentration Calculation of
size pick-up rate
Precision Auto Leveler dramatically improves the
the size box to ensure that a consistent amount
of size is applied to the yarn. The system Estimated size concentration accuracy of sliver weight fluctuation corrections. The Highest Standards for Ease of

constantly checks the moisture content of the
yarn following the pre-wet process and the Flow meter Flow meter
Fast CPU cuts the scanning length needed to sense variations Operation and Maintenance
amount of size pick-up to the yarn, and in sliver weight to one-third the previous distance for
compares these values to the estimated size higher accuracy. New machine status monitor lets the operator
Size supply
concentration in the size box. Based on the Improved servomotor responsiveness provides further check key data parameters anytime.
results, the pre-wet squeezing pressure is Water supply
boosts in accuracy.
adjusted according to the type of product being Squeezing Sizing length
Concentration of
size to be supplied Stainless-steel coiler plates offer superior
loomed, and the size concentration in the size pressure control
box is maintained at a consistent level. Warp yarn unit volume
abrasion resistance.
Water supply control Yarn production
volume calculation Size supply control

Pre-wet moisture control

High SpeedsUp to 1,000 Meters/Minute

5-Over 4+ Pressure Bar Draft

The optimized sliver feed path and Auto Leveler ensure high-quality sliver The 5-Over 4+ Pressure Bar Draft is highly rated for delivering stable,
Easy Change-Over Existing
Equipment
Multi-Purpose System forming, enabling fast, efficient operation at speeds of up to 1,000 m/min. consistent drafting. Separating the main draft zone and break draft zone
Switching over to the pre-wet sizing Top squeezing roller For products that require no pre-wet sizing, the pre-wet sizing system can be under actual operating conditions. allows the top rollers to grasp the fleece reliably, ensuring stable,
system only involves replacing the used as a conventional carrier roller system. consistent draft.
Bottom squeezing roller
existing carrier roller system.
(Note: Only possible on our sizing
Compact Roller Arrangement Drawing speed (m/min.)
Type
The roller configuration is designed to minimize the distance between the 400 500 600 700 800 900 1000 6 to 8 1.02 1.1 to 1.7
machines delivered after 1985.)
point where pre-wet squeezing takes place and the point where the yarn is Combed
100% cotton Main draft Break draft
Sizing frame Carded
Carrier roller frame immersed in the size. This roller configuration makes the moisture content
Polyester/cotton blend
following squeezing less likely to be affected by factors in the external

Synthetic
100% polyester

fiber
After Upgrade environment. It also offers the additional advantage of making it easier for the 100% acrylic
operator to deal with machine stops, such as repairing warp breaks. 100% rayon
Top squeezing roller
Squeezing rollers
Eliminates Pre-Drying
Bottom squeezing roller
Super-high-pressure squeezing and precise control of squeezing pressure in
the pre-wet section ensure consistent, stable moisture content in the yarn
following squeezing. This eliminates the need to pass the yarn through a pre- Pressure bar draft
Pre-wet frame
Sizing frame drying stage and provides sufficient pre-wetting effect resulting in excellent Improved Servomotor Responsiveness

yarn handling characteristics and greater energy efficiency.
Servomotors designed to provide superior responsiveness and tracking
characteristics offer better accuracy in compensating for variations in sliver
weight.

Pre-Wet Sizing Benefits

Cuts Size Consumption Typical Examples Using Cotton Yarn Typical Examples Using Polyester/Cotton Blended Yarn Comparative Servomotor Responsiveness Monitoring System

The effectiveness of pre-wet sizing will vary rpm An advanced monitoring system enables
Yarn No. of Standard Pre-wet Size Yarn No. of Standard Pre-wet Size 450
depending on the type of yarn, yarn count, count ends pick-up rate pick-up rate concentration count ends pick-up rate pick-up rate concentration the operator to change settings such as
400
size used, and the actual amount of size switching the Auto Leveler ON or OFF,
160/2 13800 4 25 3 11 45s 6260 13 30 9 12 350
pick-up to the yarn, but reductions of 20% and to enter operating conditions. The
300
to 40% in the amount of size required can 60s 8840 8 25 6 10 34s 4992 12 33 8 12 system can also store a diverse range of
250
DX8
be expected. Cutting size consumption 200 operating data, including production
60s 13200 8 25 6 11 30/2 6600 7 42 4 8
facilitates the desizing process and reduces 150
Conventional model control and spinning quality control
finishing costs. In addition, the benefits of 50s 6976 9 33 6 10
100 items, maintenance data, and machine
resource conservation and reduced 40s 6368 33 10 50 downtime statistics. Necessary data can
9 6
industrial waste also contribute to a cleaner 0 Elapsed time be readily retrieved for use whenever
20s 5200 7 42 4 8 0 200 400 600 800 1000 1200 1400 1600 1800 2000 (units: 0.5 ms)
natural environment. needed.

4 5
 Technical News What's New

Toyota Spun Sizer

Pre-Wet Sizing System DX8 High-Speed Drawing Frame Debuts
The Toyota DX8 High-Speed Drawing Frame takes
Cuts Sizing Costs and Helps Keep the Environment Clean
quality, productivity and ease of use to even higher
What

is Pre-Wet Sizing? levels, precisely meeting diverse customer needs.
Pre-wet sizing involves passing the yarn through hot water and
Squeezing
squeezing out excess moisture before applying size. Running the
yarn through a preliminary hot water box removes cotton wax and
Sizing
Offers High Levels of Both Quality and
foreign matter, which allows the size to penetrate the yarn more Productivity

smoothly, and enables a thinner, more uniform size application. This Soaking in

makes it possible to cut size consumption, and also provides the

hot water Optimized sliver feed path
added benefit of reducing the amount of size that must be removed (feed, draft, coiling, etc.)
in the finishing process that would normally enter the industrial Hot water box Size box
Twist-free in-line sliver feed enables precise weight
waste stream, resulting in a cleaner environment. measurement.
Newly designed sliver guides provide optimal
sliver feed width.
Toyota Pre-Wet Sizing System Features Newly designed gatherer forms slivers with fleece wrapped
inside and with no fuzz.
SIZE-NAVI System
This system controls the size concentration in Calculation of
actual moisture content
Target size concentration Calculation of
size pick-up rate
Precision Auto Leveler dramatically improves the
the size box to ensure that a consistent amount
of size is applied to the yarn. The system Estimated size concentration accuracy of sliver weight fluctuation corrections. The Highest Standards for Ease of

constantly checks the moisture content of the
yarn following the pre-wet process and the Flow meter Flow meter
Fast CPU cuts the scanning length needed to sense variations Operation and Maintenance
amount of size pick-up to the yarn, and in sliver weight to one-third the previous distance for
compares these values to the estimated size higher accuracy. New machine status monitor lets the operator
Size supply
concentration in the size box. Based on the Improved servomotor responsiveness provides further check key data parameters anytime.
results, the pre-wet squeezing pressure is Water supply
boosts in accuracy.
adjusted according to the type of product being Squeezing Sizing length
Concentration of
size to be supplied Stainless-steel coiler plates offer superior
loomed, and the size concentration in the size pressure control
box is maintained at a consistent level. Warp yarn unit volume
abrasion resistance.
Water supply control Yarn production
volume calculation Size supply control

Pre-wet moisture control

High SpeedsUp to 1,000 Meters/Minute

5-Over 4+ Pressure Bar Draft

The optimized sliver feed path and Auto Leveler ensure high-quality sliver The 5-Over 4+ Pressure Bar Draft is highly rated for delivering stable,
Easy Change-Over Existing
Equipment
Multi-Purpose System forming, enabling fast, efficient operation at speeds of up to 1,000 m/min. consistent drafting. Separating the main draft zone and break draft zone
Switching over to the pre-wet sizing Top squeezing roller For products that require no pre-wet sizing, the pre-wet sizing system can be under actual operating conditions. allows the top rollers to grasp the fleece reliably, ensuring stable,
system only involves replacing the used as a conventional carrier roller system. consistent draft.
Bottom squeezing roller
existing carrier roller system.
(Note: Only possible on our sizing
Compact Roller Arrangement Drawing speed (m/min.)
Type
The roller configuration is designed to minimize the distance between the 400 500 600 700 800 900 1000 6 to 8 1.02 1.1 to 1.7
machines delivered after 1985.)
point where pre-wet squeezing takes place and the point where the yarn is Combed
100% cotton Main draft Break draft
Sizing frame Carded
Carrier roller frame immersed in the size. This roller configuration makes the moisture content
Polyester/cotton blend
following squeezing less likely to be affected by factors in the external

Synthetic
100% polyester

fiber
After Upgrade environment. It also offers the additional advantage of making it easier for the 100% acrylic
operator to deal with machine stops, such as repairing warp breaks. 100% rayon
Top squeezing roller
Squeezing rollers
Eliminates Pre-Drying
Bottom squeezing roller
Super-high-pressure squeezing and precise control of squeezing pressure in
the pre-wet section ensure consistent, stable moisture content in the yarn
following squeezing. This eliminates the need to pass the yarn through a pre- Pressure bar draft
Pre-wet frame
Sizing frame drying stage and provides sufficient pre-wetting effect resulting in excellent Improved Servomotor Responsiveness

yarn handling characteristics and greater energy efficiency.
Servomotors designed to provide superior responsiveness and tracking
characteristics offer better accuracy in compensating for variations in sliver
weight.

Pre-Wet Sizing Benefits

Cuts Size Consumption Typical Examples Using Cotton Yarn Typical Examples Using Polyester/Cotton Blended Yarn Comparative Servomotor Responsiveness Monitoring System

The effectiveness of pre-wet sizing will vary rpm An advanced monitoring system enables
Yarn No. of Standard Pre-wet Size Yarn No. of Standard Pre-wet Size 450
depending on the type of yarn, yarn count, count ends pick-up rate pick-up rate concentration count ends pick-up rate pick-up rate concentration the operator to change settings such as
400
size used, and the actual amount of size switching the Auto Leveler ON or OFF,
160/2 13800 4 25 3 11 45s 6260 13 30 9 12 350
pick-up to the yarn, but reductions of 20% and to enter operating conditions. The
300
to 40% in the amount of size required can 60s 8840 8 25 6 10 34s 4992 12 33 8 12 system can also store a diverse range of
250
DX8
be expected. Cutting size consumption 200 operating data, including production
60s 13200 8 25 6 11 30/2 6600 7 42 4 8
facilitates the desizing process and reduces 150
Conventional model control and spinning quality control
finishing costs. In addition, the benefits of 50s 6976 9 33 6 10
100 items, maintenance data, and machine
resource conservation and reduced 40s 6368 33 10 50 downtime statistics. Necessary data can
9 6
industrial waste also contribute to a cleaner 0 Elapsed time be readily retrieved for use whenever
20s 5200 7 42 4 8 0 200 400 600 800 1000 1200 1400 1600 1800 2000 (units: 0.5 ms)
natural environment. needed.

4 5
 Customer Support & Service THOUGHTS & FEELINGS
User Report Beijing

Electronic Parts Catalog

(for the JAT710) Part 14 China
China
Shanghai

Designed for Customer Convenience

We have recently created an electronic version of the parts catalog for the
Shandong Weiqiao Shandong Weiqiao
new JAT710 Air Jet Loom. This CD-ROM is designed to make using the
catalog as easy as possible for our customers, and includes convenient
Textile Group Co., Ltd. Textile Group Co., Ltd.
No. 34 Qidong Road, Weiqiao Town,
Zouping County, Shandong Province, China

features such as part lists linked to part illustrations, as well as the ability to In this issue, we introduce the Shandong Weiqiao
search by part number and/or description and generate parts order lists. Textile Group Co., Ltd, the leader in net sales and
Customers can use the illustrations contained in the catalog to create manufacturing volume in the Chinese textile
documents such as operation sheets and factory reports. The CD-ROM also industry. Located in the southern part of North
contains the catalog data in printable form for customers who wish to have a Shandong Plain, Shandong Province, the company
hardcopy version of the catalog available. has a 2,000-hectare site and 60,000 employees.
Shandong Weiqiao has plants for spinning,
Search weaving, dyeing, as well as its own thermal power
Users Guide
Provides instructions on how to use the parts
Specify a part number, part name or plant. The groups annual capacity is 300,000 tons
remarks as search parameters.
catalog.
Wildcard searches are also possible (use
of cotton yarn and 1.1 billion meters of cotton
Available in three languages: Japanese, Chinese cloth. Shandong Weiqiao was the first company in
to indicate any text before or after, and
and English *? to indicate any single character). China to use our RX240NEW-EST ring spinning
frame, and now has 20,000 spindles. This year, the
Parts Order company ordered more than 900 of our new
An Order List can be generated automatically JAT710 air jet looms.
simply by checking the appropriate checkbox in
the column next to a needed part.
Enter the quantity needed and click the SAVE
button to save the file in CSV format.
Send the Order List by e-mail, or upload the file
from the TICS (Toyota Internet Customer
System) screen*.

Part Numbers Linked to

*You must sign a basic services agreement to use TICS.
Part Illustrations
Key nos. in part illustrations are linked to
In addition to the parts catalog, the instruction manual is
also provided in electronic form. The instruction manual can the part number list. Selecting one
also be printed out, if desired. automatically causes the other to be
Application software needed to view the CD-ROM versions selected, as indicated by a color change.
of the parts catalog and instruction manual is also provided
on the CD-ROM.

Zhang Shiping, Chairman Zhang Hongxia, General Manager

Maintenance Tips from the Service Department
Thank you very much for choosing textile machinery from Toyota.
Continuing from the previous issue, we are pleased to offer a few helpful maintenance tips selected by our service personnel.
Air Jet Looms
1. Air compressors form the heart of air jet looms.
These devices are susceptible to contamination
from oil and condensed moisture, and even a small
amount entering the unit will make it impossible for
the compressor to deliver maximum performance.
Be sure to change the mist separator and filters on
the compressor outlets on a regular basis. Regular
replacement of these maintenance items will ensure
stable, consistent operation, save energy, and
enable you to maintain high uptime ratios.
2. When the reed is washed on the loom, be very
careful to ensure that no washing solution splashes
on the weft yarn detector or valves. Water
splashing onto electrical components will reduce
reliability significantly. When washing, be sure to
use protective caps and waterproof sheeting to
protect these components.
3. Damaged healds coming into contact with the heald
frame have the potential to cause catastrophic
damage. Be sure to remove and replace damaged
healds immediately.
Water Jet Looms
1. Cushion washers located inside magnetic pins
installed on two-color or BLD measuring systems
must be checked (or replaced) at least once a year.
If neglected, a worn or damaged washer may
cause failure/damage or abrasion problems on
cores or plungers.
2. Lint or waste yarn wrapped around the outside of
the main shaft coupling (right side) can damage
the oil seal tip, allowing moisture to penetrate into
the gear box. When the beams become empty, be
sure to completely remove any lint or yarn waste,
and perform an oil check.
3. On occasion, customers may switch to contactor-
type inching on their inverter-type inching models.
This mode of operation shortens the service life of
magnetic contactors, and we strongly advise
against this kind of usage.
Mitsuhiro Iwasaki, Service Department Manager
Spinning Machinery
1. Uniform roving tension during spinning is
essential to ensure stable operation. Running
equipment with improper tension will cause
increased downtime resulting from roving breaks
and lead to poor yarn quality in downstream
processes. Be sure to pay careful attention to
roving tension.
2. Items to check when roving tension is out of
specifications:
1) Abrasion on flyer cap (recommended
replacement period: every 3 to 5 years)
2) Abrasion on flyer presser (recommended
replacement period: every 3 to 5 years)
3) Increased contact resistance due to cotton wax
adhering to the flyer.
4) Out-of-level condition of bottom conveyor drum
and/or faulty building motion adjustment.
5) Inner surface abrasion on conveyor belts and/or
increased slippage resulting from the use of
other than genuine factory parts.
Tell us about the products you make.
We make more than 2,000 kinds of cloth, including pure cotton
cloth, polyester cloth, fine-count/high-density stretch cloth,
denim (standard yarn, stretch yarn, slub yarn), corduroy, and
synthetic fiber cloth. With ISO 9001 quality management
certification, we make the Weiqiao brand, which we ship to more
than 20 countries, including the US, Japan, and Korea and which
is highly rated among customers for its superb quality. Our
quality policy is with people as our capital, take the utmost care
in the manufacture of all yarn and cloth, and work with sincerity
to create new products that will satisfy customers.
What do you think of the Toyota products you use?
Toyota has the highest level of
technology and we have complete
faith in its products. We purchased
20,000 spindles of Toyotas
compact RX240NEW-EST ring
spinning frame in efforts to further
raise our own level of technology. With the market today
demanding the very highest quality fabric, our goal is to use
Toyota machinery to produce a higher grade of compact yarn
that gives our customers added value and that makes us a
leader in the high-end market. We look forward to continued
support from Toyota.
What are your companys plans for the future?
In 2000, we made it our goal to become a pioneer in the
worldwide spinning and weaving industries in the 21st century.
Another goal is to raise our earnings in 2005 to quadruple those
of 2000. In other words, were aiming for net sales in 2005 of
15 billion yuan (US$1.814 billion), with US$600 million of that
being exports. On a foundation of spinning and weaving, we
hope to make our company grow in two major areas: spinning,
weaving, dyeing, and sewn products; and thermal power,
aluminum electrolysis, and aluminum processing.
Toyota air jet looms at work in
the Shandong Weiqiao plant

6 7
 Customer Support & Service THOUGHTS & FEELINGS
User Report Beijing

Electronic Parts Catalog

(for the JAT710) Part 14 China
China
Shanghai

Designed for Customer Convenience

We have recently created an electronic version of the parts catalog for the
Shandong Weiqiao Shandong Weiqiao
new JAT710 Air Jet Loom. This CD-ROM is designed to make using the
catalog as easy as possible for our customers, and includes convenient
Textile Group Co., Ltd. Textile Group Co., Ltd.
No. 34 Qidong Road, Weiqiao Town,
Zouping County, Shandong Province, China

features such as part lists linked to part illustrations, as well as the ability to In this issue, we introduce the Shandong Weiqiao
search by part number and/or description and generate parts order lists. Textile Group Co., Ltd, the leader in net sales and
Customers can use the illustrations contained in the catalog to create manufacturing volume in the Chinese textile
documents such as operation sheets and factory reports. The CD-ROM also industry. Located in the southern part of North
contains the catalog data in printable form for customers who wish to have a Shandong Plain, Shandong Province, the company
hardcopy version of the catalog available. has a 2,000-hectare site and 60,000 employees.
Shandong Weiqiao has plants for spinning,
Search weaving, dyeing, as well as its own thermal power
Users Guide
Provides instructions on how to use the parts
Specify a part number, part name or plant. The groups annual capacity is 300,000 tons
remarks as search parameters.
catalog.
Wildcard searches are also possible (use
of cotton yarn and 1.1 billion meters of cotton
Available in three languages: Japanese, Chinese cloth. Shandong Weiqiao was the first company in
to indicate any text before or after, and
and English *? to indicate any single character). China to use our RX240NEW-EST ring spinning
frame, and now has 20,000 spindles. This year, the
Parts Order company ordered more than 900 of our new
An Order List can be generated automatically JAT710 air jet looms.
simply by checking the appropriate checkbox in
the column next to a needed part.
Enter the quantity needed and click the SAVE
button to save the file in CSV format.
Send the Order List by e-mail, or upload the file
from the TICS (Toyota Internet Customer
System) screen*.

Part Numbers Linked to

*You must sign a basic services agreement to use TICS.
Part Illustrations
Key nos. in part illustrations are linked to
In addition to the parts catalog, the instruction manual is
also provided in electronic form. The instruction manual can the part number list. Selecting one
also be printed out, if desired. automatically causes the other to be
Application software needed to view the CD-ROM versions selected, as indicated by a color change.
of the parts catalog and instruction manual is also provided
on the CD-ROM.

Zhang Shiping, Chairman Zhang Hongxia, General Manager

Maintenance Tips from the Service Department
Thank you very much for choosing textile machinery from Toyota.
Continuing from the previous issue, we are pleased to offer a few helpful maintenance tips selected by our service personnel.
Air Jet Looms
1. Air compressors form the heart of air jet looms.
These devices are susceptible to contamination
from oil and condensed moisture, and even a small
amount entering the unit will make it impossible for
the compressor to deliver maximum performance.
Be sure to change the mist separator and filters on
the compressor outlets on a regular basis. Regular
replacement of these maintenance items will ensure
stable, consistent operation, save energy, and
enable you to maintain high uptime ratios.
2. When the reed is washed on the loom, be very
careful to ensure that no washing solution splashes
on the weft yarn detector or valves. Water
splashing onto electrical components will reduce
reliability significantly. When washing, be sure to
use protective caps and waterproof sheeting to
protect these components.
3. Damaged healds coming into contact with the heald
frame have the potential to cause catastrophic
damage. Be sure to remove and replace damaged
healds immediately.
Water Jet Looms
1. Cushion washers located inside magnetic pins
installed on two-color or BLD measuring systems
must be checked (or replaced) at least once a year.
If neglected, a worn or damaged washer may
cause failure/damage or abrasion problems on
cores or plungers.
2. Lint or waste yarn wrapped around the outside of
the main shaft coupling (right side) can damage
the oil seal tip, allowing moisture to penetrate into
the gear box. When the beams become empty, be
sure to completely remove any lint or yarn waste,
and perform an oil check.
3. On occasion, customers may switch to contactor-
type inching on their inverter-type inching models.
This mode of operation shortens the service life of
magnetic contactors, and we strongly advise
against this kind of usage.
Mitsuhiro Iwasaki, Service Department Manager
Spinning Machinery
1. Uniform roving tension during spinning is
essential to ensure stable operation. Running
equipment with improper tension will cause
increased downtime resulting from roving breaks
and lead to poor yarn quality in downstream
processes. Be sure to pay careful attention to
roving tension.
2. Items to check when roving tension is out of
specifications:
1) Abrasion on flyer cap (recommended
replacement period: every 3 to 5 years)
2) Abrasion on flyer presser (recommended
replacement period: every 3 to 5 years)
3) Increased contact resistance due to cotton wax
adhering to the flyer.
4) Out-of-level condition of bottom conveyor drum
and/or faulty building motion adjustment.
5) Inner surface abrasion on conveyor belts and/or
increased slippage resulting from the use of
other than genuine factory parts.
Tell us about the products you make.
We make more than 2,000 kinds of cloth, including pure cotton
cloth, polyester cloth, fine-count/high-density stretch cloth,
denim (standard yarn, stretch yarn, slub yarn), corduroy, and
synthetic fiber cloth. With ISO 9001 quality management
certification, we make the Weiqiao brand, which we ship to more
than 20 countries, including the US, Japan, and Korea and which
is highly rated among customers for its superb quality. Our
quality policy is with people as our capital, take the utmost care
in the manufacture of all yarn and cloth, and work with sincerity
to create new products that will satisfy customers.
What do you think of the Toyota products you use?
Toyota has the highest level of
technology and we have complete
faith in its products. We purchased
20,000 spindles of Toyotas
compact RX240NEW-EST ring
spinning frame in efforts to further
raise our own level of technology. With the market today
demanding the very highest quality fabric, our goal is to use
Toyota machinery to produce a higher grade of compact yarn
that gives our customers added value and that makes us a
leader in the high-end market. We look forward to continued
support from Toyota.
What are your companys plans for the future?
In 2000, we made it our goal to become a pioneer in the
worldwide spinning and weaving industries in the 21st century.
Another goal is to raise our earnings in 2005 to quadruple those
of 2000. In other words, were aiming for net sales in 2005 of
15 billion yuan (US$1.814 billion), with US$600 million of that
being exports. On a foundation of spinning and weaving, we
hope to make our company grow in two major areas: spinning,
weaving, dyeing, and sewn products; and thermal power,
aluminum electrolysis, and aluminum processing.
Toyota air jet looms at work in
the Shandong Weiqiao plant

6 7
 T O Y O T A @ W O R K Vol. 15
Introducing Toyotas Businesses Part IV Engine Division
This is the 4th installment in our series on Toyota business
divisions. The Engine Division develops and manufactures
diesel and gasoline engines from 1.5 to 4.7 liters. These
TO YOTA TE XTI LE MA CH IN ER Y
engines go into Toyota Motor Corporation passenger cars and

B U L L E T I N
Toyota Industries forklifts.

Based on its motto of Quality No. 1, the Engine

Division constantly strives to make high-power, fuel-
efficient, low-noise and low-vibration engines that are
Engine Division History constructed from recyclable materials and that thus
1953 Kyowa Plant begins manufacturing passenger car engines. achieve both environmental friendliness and superb
1982 Hekinan Plant goes on line manufacturing diesel engines efficiency. The Hekinan Plant, which started operation
for passenger cars. in 1982, boasts lines equipped with unmanned
1991 Engine production reaches 5 million. transport machinery and rest and relaxation facilities,
1998 Engine production reaches 8 million. giving employees an environment conducive to healthy,
2001 Engine production reaches 9 million. productive work.

Main Products

1CD-FTV 2,000 cc engine

for small passenger cars
A direct diesel-injection engine used in cars like
the Estima and Corolla in Japan, and in the
Avensis, RAV4, and Corolla in Europe.
2UZ-FE 4,700 cc engine for large RVs
Used in both the domestic and export versions of
all Land Cruiser models except the Prado. This
diesel engine is also used in the Coaster.
4Y 2,200 cc engine for industrial vehicles
Used in industrial vehicles like forklifts, and for
driving gas heat pumps and bus coolers.
2 Special Feature
JAT710s IT Functions

4 Technical News
Toyota Spun Sizer Pre-Wet Sizing System
About the Cover: Japanese DesignIn Style to Stay
The Western fashion world has witnessed a wave of Japonismthe love of things Japanesein 5 Whats New
2-1, Toyoda-cho, Kariya-shi, Aichi 448-8671, Japan recent years. No longer merely relegated to the realm of the kitsch, esoteric, and foreign, todays DX8 High-Speed Drawing Frame
Tel: 81-566-27-5326 Fax: 81-566-27-5307 Japanese fashion boasts patterns of intricate, graceful beauty and is equal in status to its Western
URL: http://www.toyota-industries.com/textile
counterpart. Visitors to Japan love to take home not only Japanese-patterned clothing but also
knick-knacks like hand mirrors and fans.
6 Customer Support & Service
E-mail: kaoru.kumamoto@mail.toyota-shokki.co.jp Electronic Parts Catalog
Tips from the Service Department
Please send your comments or questions regarding the TOYOTA TEXTILE MACHINERY
Toyota Textile Machinery Bulletin to any of the above addresses. BULLETIN Vol.15 7 Thoughts & Feelings
Contact person: Ms. Kaoru Kondo User Report Part 14:
Published July 2003
Shandong Weiqiao Textile Group Co., Ltd. (China)
Art direction and editorial assistance: Cs Inc. All rights reserved. Reproduction in whole or in part without written permission is
Printing: Okamura Printing Industries Co., Ltd. prohibited. This bulletin is printed on recycled paper.
8 Toyota @ Work
Introducing Toyotas Businesses
Part IV: Engine Division
Printed in Japan
8