Program: Bachelor of Science in Business Administration

Course: Production and Operations Management

Review: Toyota Manufacturing Processes

Topics Covered:
• Kaizen and Just In Time
• Management of Production Processes
• Manufacturing Processes

Objectives:
At the end of activity, the students are expected to:
• To be able to understand the production process of vehicles especially cars
• Understand the manufacturing process of large production company

Instructions:

Each student is required to watch a manufacturing documentary of Toyota- a video of production

process where they will understand the different areas of manufacturing a car. The student should visit
the site or search ‘’Toyota production documentary’’ on the internet browser. The student will discover
the manufacturing process of cars of Toyota. Consider the following to review a Super Bowl Ad or Any
one of the Top Ads.

Television commercials are specific type of art and they created to pursuade the consumer to buy a
specific product. Your analysis must include the following:

• Describe the overall Manufacturing Process in Toyota.

• Besides consumer, who else are the consumers of Toyota Products?
• Where are the Manufacturing Site is located and how wide is the area?
• What do you observe in the process of building the body shell of Toyota cars?
• What are the 8 Processes of Painting Toyota cars?
• Robotics and high technology is being opinion regarding the use of technology in Production
Process?
• What is the Importance of using both manpower and technology in Manufacturing Process?
• Give your insights about how our local manufacturers improve their Production Process.
• Cite some local manufacturers or Filipino Companies that you think are using effective
Manufacturing Process.
A Toyota Motor Manufacturing Kentucky or TMMK are combining the time principles of one of the
worlds leading out of makers with hands on skill and dedication to build a high standard quality in
America made vehicle. TMMK is located in Georgetown, Kentucky, United States. The site covers 7.5
million square feet of floor space with the equivalent of 156 football fields on the roof. This is one of
the most complete vehicular manufacturing plants in the world. Each day TMMK members put into
action to production system known across the world’s quality, safety and efficiency.

The production process starts from using computer controlled lasers technology to hand grinding tools.
The team members bring the designers plans to life with quality measured within 200thd of a
millimeter. A shop covers about 700 thousand square feet. The dyes will be loaded into one of more
than 30 presses in the shop to do their jobs. It takes about 20 hours to complete one vehicles. The
Toyota Motor Manufacturing Process has Four (4) Production Process, The Stamping Process, Welding
Process, Painting Process and Assembly Process.

The Stamping Process is the cutting of sheet metal and stamped to form hoods, doors, and other body
parts of a vehicle. The stamping begins with making Giant Coils of steel weighing up to 24 tons. Team
members on the floor move the coils using remote control overhead crane. The coil loaded into one of
the four blanking machines, which straighten and clean the metal, then the machine cuts the metal into
blanks. The blanking machines cut the steel at the rate of 80 strokes per minute, using a force of nearly
up to 800 times. The finished blanks are fed into stackers that are automatically stop at the beginning
and the end of production for quality check. They check how many times the quality of the vehicle
during the production process. When blanks pass inspection there moved to storage by a Forklift
Operator, they stay there until they’re needed on the stamping lines then the driver will deliver the
blanks to the press. In Stamping Team TMMK uses more than 20 automated press lines in more than 30
presses loaded with some 900 dies weighing as much as 40 tons each. These dyes come together with
up to 2600 tons of pressure to bend shape and trim the blanks into formed vehicle parts. To withstand
an impact so strong the floor beneath the presses is nearly 3 feet of solid concrete. The larger pressers
also rest on several concrete pillars that go as deep as 30 feet below. The shop floor in this basement
metal scraps trimmed from the parts during stamping fall onto a conveyor and are collected for
recycling throughout their plant. They recycle and reuse as much material as possible in order to be a
good steward of the environment when a different part is needed dye changes are required for many
plants. This is a time consuming process but a team TMMK, they have the process down to about 10
minutes at the end of stamping lines team members inspect the parts as they come off the presses once
approved the parts are stored for a short time until they’re needed by the Body Weld Department.

The second Production Process is the Welding Process, approximately 400 body parts are welded by
robots to form exterior of the vehicle. In about 2 hours the Body Weld builds a complete body shell the
shop covers about 1 million square feet and is the most automated part of the plan its team members
work with with some 700 body robots. Body Weld is divided into four lines, Under Body Resisting
Spot Welding (RSW), Under Body Tacking, Main Framing Body and Body Shell. Here in Under Body
Resisting Spot Line, three major sections of under body come together the engine compartment, the
front floor, the engine compartment and the rear floor. Then the under body will move to the main
framing body line where it will join to the quarter panels, the roof the cow and the upper back of the
vehicle. Alongside team members more than 70 computer controlled robots perform the thousands of
precision welds required. Next line, the vehicles bodies are lifted onto the overhead conveyor and taken
to the body shell line. The last line in body weld on the body shell team members attach various parts
including trunk lids, doors, hoods and fenders. After final inspection and approval completed body
shelves travel by conveyor to our paint shop or they may head to shipping if they are among more than
350 replacement parts that are stamping and body weld shops supply to dealers and other customers
around the world. These shops produce repair parts for our vehicles for at least 10 years after TMMK
stops producing of a model.

The third Production Process is the Painting Process, the welded body parts and then given an
undercoat, middle coat and top coat of paint to produce a high-quality painted finish. Here in paint a
body shell gets what will be one of the vehicles most defining qualities its color and the guard. The
quality of that paint job very closely throughout paint care is taken to keep debris out because even one
speck of dust can ruin a paint finish. As team members enter the shop they the shop they done special
lint-free clothing and walk through an air blow room the air removes any loose hair thread or material
that may diminish the quality of our paint jobs. These team members working in paint also must be
mindful of how personal products might affect the paint process. Our paint process takes about 10 and
half hours to complete starting when a completer body show is pulled from weld. The pull system is an
aspect of Toyota Production System Just-In-Time Concept. When material or a component like a body
show is needed its pulled to the shop not pushed as in many traditional manufacturing facilities by
pulling instead of pushing. They produce only what they need, when they need it and in the amount
needed.

Painting in Toyota Involves 8 Basic Processes, but First, the body shell must be cleaned a series of dips
into tanks removes dirt grease and other contaminants from the surface then the painting begins with a
dip into the Phosphate Tank Process that itches the body shell so primer and topcoat will better adhere
to it. The second process is the ED Dip Electro Deposition is an electronically charged primary that
permanently bonds to the shell after ED Dip the body goes through a series of rinses then is Oven-
baked at nearly 500 degress. The third process is the Dry and Sealing team members smooth rough
spots on the body surface then robots apply a seam sealer to prevent corrosion and water leaks. The
fourth processis the Anti Chip, this is applied to the bottom of our vehicles where they will receive the
most road damage. The fifth process is the Applying of Primer to smooth out the appearance of
previous layers then the body shell is baked again in more than 250 degrees. The Sixth process is the
Wet Sand, here the shell will get its final preparation before painting with team members. Inspecting it
and removing any last imperfections. The seventh process is the Top Coat, In one of three painting
booths this area is another example of Toyota’s commitment to the environment our paint robots use a
unique cartridge and water-based system that let them quickly switch between paint colors with little
waste of paint or the use of harsh chemicals. The robots also are programmed to paint along the contour
of the vehicle this reduces the amount of over spray that enters our reclamation system. Last process is
the Final Inspection, the painted shell is baked again around 250 degrees for about a half an hour then
the painted body is checked for any imperfections. They will approved vehicles go to the selectivity
bank ready to be pulled to assembly when needed.

The Fourth Production Process is the Assembly Process, the various parts are attached to painted body
such as the engine and tires. The fully-assembled vehicle is subjected to a strict quality check in the
inspection process and is the shipped as a finished automobile. While the body shell is being welded
and painted our power train shop is building the vehicles engine. TMMK produces more than 2000
engines a day on site. They build both four and six Cylinder engines in this 1.2 million square foot
shop. Power Trains raw materials include engine blocks and heads that come form our suppliers.
TMMK has more than 350 suppliers in North America over 100 of which are located in Kentucky
power train machines, its camshafts, crank shafts, connecting rods, cylinder blocks, cylinder heads,
cam housing and piston pins from our suppliers. RUF castings, the machine components are sent to
short block sub assembly.
First Assembly, team members install the crankshaft, pistons and piston pins assemblies after the
engine receives a balance shaft for vibration reduction. It moves to lower assembly. The second
Assembly process, a team member positions the oil pan just before a machine inserts and tightens the
oil pan bolts if the machine detects any problems, it will stop and send a signal to alert the team leader.
This is another key part of the Toyota Production System, the VIDYUKA is the practice of stopping
production whenever a problem is detected. Many of the machines will automatically do this and the
team members can do this as well to keep any flaws out of the products. Third, the team members
installs the timing belt, timing cover and oil and water pumps as the engine moves down its line. Team
members confirms their work and that of previous processes in the final production stage. Then the
engine gets its Cylinder head wire, harness intake, and exhaust systems once completed the quality of
our engines is confirmed in a test cell. The engines are subjected to several tests as team members
evaluate them for noise emissions and any abnormalities approved engines are sent to a shipping route
which holds a 2 to 3 hour supply of engines. Team members of our conveyance team will come to
collect the engines that are needed when they are needed by assembling they’ll be delivered JUST-IN-
TIME.

Our assembly plants also get parts from our on site Plastic Shop, in this 517 thousand square meters
foot shop, team members produce components for our vehicles including interior trim, rocker panels,
manifolds, front and rear bumpers and instrument panels. Making the instrument panel or IP starts in
the injection molding area where plastic pellets are melted and then injected into a mold under several
hundred tons of pressure at more than 400 degrees to form the instrument panels skeleton which we
call a SUBSTRATE.

Nearby into Slush Molding Area, molds are filled with a very fine powder and are heated and cooled
over several processes to create the skin of the instrument panel in plastic. IP assembly team members
combine the skin and substrate and add padding made of recycled materials as well as other parts from
within the shop from vendors.

Shops Injection Molding Area, team members make trim for the vehicles interior and produce the
manifold they injection mold each piece. Then combine them using an Ultrasonic Welder Robots load
the parts into the machine which uses high-frequency sounds to weld them together then the manifolds
pass to the Manifold Assembly Line, where they are fitted with gaskets and parts to ready them for
vehicle installation. This shop also makes vehicle bumpers after they are formed by Injection Molding.
The raw bumpers are primed and painted in plastics in much the same way as the vehicle body is
painted in our paint. Apart Rocker Panels are also created and painted in this shop using the same
process while plastics applies assembly with these two parts.

The shop also ships them to our Sister Camry Plant in Indiana and to dealers as service parts. TMMK
Plastics ships about 1000 service parts each day, They supply service parts for up to 21 years after the
production stops for a model. The machines and plastics are kept running by the shops Maintenance
Team members while another set of skilled tool and die. Team members repair molds and dies at the
end of each plastics. Process Team members inspect their parts for quality and then load them onto ah
parts carrier for delivery to the next process including assembly.

TMMK assembly shops are the largest in the Plant Covering nearly 2million square feet Assembly 1.
Our original Plant builds Avalon and camera while Assembly 2 produces Camry and Venza, each shop
is comprised of three operations or Lines, Trim, Chassis and Final Assemblies.
Work begins when it pulls a newly painted body shell from paint. Trim line installs parts largely unseen
by customers like wiring, harnesses, onboard computers and padding that will keep the vehicles interior
quiet. Team member places a Manifest Sheet on each vehicle this sheet tells team members which parts
and which options to install on each vehicle. Car also gets is set of Keys, they will travel the length of
the line with the vehicle as parts for each vehicle are needed. They are delivered line side by hour
Conveyance Team Members. Parts arrive from our suppliers constantly throughout the day orchestrated
by our production.

Control Department using JUST-IN-TIME System to minimize inventories and space. The plant
typically stocks on site only the parts needed for about 3 hours of production. As parts arrive some go
directly to the line like seats which are already in perfect order to match the vehicle in which they’re
going to be installed. Most parts however are brought here to our Dock Area where our team members
sort and prepare them for the line. The Box, some parts for particular vehicle together into what we call
Kiting. Kiting involves parts that are small or difficult to differentiate between models. That Kit will be
delivered to the Assembly Line and often travels with the vehicle once it’s picked. Kiting is were the
Team Members focus on uality installation as the vehicle works its way down.

The Assembly Trim Line gets one of its most important features its VIN or Vehicle Identification
Number. This machine is skirting a series of numbers and letters onto a metal plate. This VIN is
installed at the base of each windshield to permanently identify the vehicle. A Team Member installs
the side Curtain Airbag, one of the first up to 10 airbags that will be installed depending on the vehicle
model. One of the first Japanese words and concepts that the Team Members learn at Toyota is
KAIZEN. It means continous improvement and is a hallmark of Toyota Production System every Team
Member contributes to Kaizen. The great example of KAIZEN is when TMMK began production in
1998 the doors stayed on the vehicles throughout the Assembly Process several years later following a
Team ever suggestion. They implemented a KAIZEN and removed the doors now, Team Members
don’t waste motion and time walking around the doors are constantly opening and closing them nor the
chance being hurt by walking into the doors the KAIZEN also reduces the possibility the doors
themselves will be damaged and they move parts racks closer to the line again reducing the Team
Members motion and time this KAIZEN developed by a Team Member helped improve safety
Ergonomics quality and productivity all in one. Once taken off the vehicle the doors travel by overhead
conveyor to a Trim Sub Assembly Line called the Door Line. The windows adding locks speakers and
other components and options are installed with the doors. The doors then head into an overhead
Conveyor System until it’s time to reinstall them to the vehicle on the Final Line. Meanwhile the door
less vehicle continues I’ts Assembly process on the trim line where the hood insulation is installed.
Padding helps keep engine noise in the passenger compartment and outside of the vehicle to an
absolute minimum.

TMMK builds Hybrid versions of many of its models and the main hybrid battery is installed weighing
more than 50 pounds. The battery is placed in the vehicle’s trunk with the help of an assistant devices
like this are used throughout the plan to help keep the Team Members safe in injury free. Trim also
installes the headliner, moon-roof trim, and visors. The team members have a certain set amount of
time to do their jobs. They call this TACK TIME. If they have a concern or encounter a problem that
keeps from meeting that tack time, they can pull the end on cord and call for help pulling the Andon
Cord that activates tunes lights and boards. The TEL Team and group leaders that they’re needed and
where they will respond and try to Address the concern without stopping the line. But if they can’t do
that during the TACK TIME, they will pull the cord again and all of production stops or if need they
will take the vehicle off line to make any needed repairs.
Next in Trim, the vehicle gets the Instrument Panel that was made in plastics. When the IP left plastics
it to IP line. Another Sub Assembly Line in Trim, team members install among other components. Air-
Conditioning Duct Work controls gauges to monitor and fuel stereo options and the steering column.
Once the IP is complete and Automatic Guided Vehicle or AGV delivers its line side for installation
into the vehicle these smarts cards are made by Team Members and follow a magnetic strip in the floor
to their destination team members use a Hoist to install the IP into the vehicle. Team members also use
a Hoist to install the rear struts which can weigh about 70 pounds each. These devices greatly reduce
the Ergonomic burden on the Team Members and help to ensure a quality installation. Trim also installs
the vehicles axles parts which are built on sire by our power train shop. Next, Gear Shift and the Rear
Tail Lights, Team Members also placed the Toyota and model emblems carefully on to the vehicle with
trims work complete the vehicle moves to Chassis a Line that is elevated because it’s work is
underneath the vehicle. Chassis team members install fuel lines, brake lines and the engine built just for
this vehicle in our Power train Shop. The Power Train Shop supplies the engine block to the engine line
in assembling. This Sub Assembly Area will build up the engine block with the air compressor,
alternator and the vehicles transmission along with other components. A Lifter holding the Engine Sub
Assembly then moves under the vehicle wgere it’s hydraulically raised into the engine compartment.
Team members both the engine to the H frame and body and then attach the axles. The exhaust and
muffler assemblies are installed afterwards. In Chassis the vehicle gets a radiator rear speakers, seat
belts and carpet.

The Quality Controlled Members inspects the work of Chassis helping to ensure that only best work is
shipped on the wheels and lug nuts are installed by this machine a Nut Runner, its used is to ensure that
all the lug nuts are tightened to the exact torque needed. The nut runner features a Poky Oak, is a fail
safe device that detects the defects and prevents them from being processed any further. Pokey Oaks
are used in conjuction with many pieces of our equipment especially critical processes to ensure safety
and quality. End of Chassis the vehicle moves to the overhead conveyor where a Robot Places this
spare tire into the truck then the vehicle descends to the Final Line.

In Final Line where Robots also help Team members install the traditional battery one robot places
batteries onto a conveyor while the Next installs the battery into the engine compartment robots also
help Final Line Team members install the vehicles windshield and rear window glass. This Final Line
Team Members is installing the center console with the help of floating chair called A RakuSee.
Another example of our JUST-IN-TIME manufacturing is our seat installation when the vehicle bodies
leave our paint shop information is sent to our seat supplier also located in Georgetown. They build the
seeds ans shipped them in sequence to match the order of vehicles on our assembly line an overhead
conveyor brings the seats directly from the delivery truck to final installation then the doors are
reunited with their original vehicle. Final also installs the cooling windshield wiper fluid, steering
wheel, windshield wipers, headlights and the bumpers.

The vehicle gets its first gasoline on final line, it enters this concrete block room where a few gallons of
gasoline are pumped into the tank. Underthis bright lights Team Members inspect every inch of the
body surface and interior closely to make sure that it will meet the Toyota high standards and quality at
the end of this line a quality control team members drives the vehicle off the line and across rumble
strips these create a vibrations which will expose any rattles or unacceptable noises . The team member
positions the vehicle on the a Tow adjust to adjust the steering wheels as another team member in the
pit below alighns the vehicle. Team members then test the vehicles functionality on a roll drum as the
vehicles move from zero to about 80 miles asn hour. Team members check for proper shifting. Next
each vehicle travels through a water shower to check for any leaks in
one of the last assembly processes the drivers steering wheel air bag is installed with this istallation of
the airbag system is initialized

randomly selected vehicles from our daily production are taken over to our audit lab and test track in
the lab team members were on quality assurance tests to check for everything from water leaks to audio
system fuctionality

at the test track highly trained team members drive the vehicles at speeds up to 85 miles an hour around
our track and over special surfaces this process confirms everything from engine performance and
handling to passenger comfort they inspact every aspect of these vehicles to ensure that only the best
quality vehicles leave our plant back in the plant each vehicle rolls off the line our customer Toyota
Motor Sales buys it From them.

Fil is added to protect the vehicle during transport then the vehicle leaves our plant for the marshalling
yard from there our vehicles are shipped to Toyota dealers across North america and the world

Every team member of TMMK has an Inspector, while doing their jobs they inspect the product to
make sure that no defects are passed on to their customer at Toyota the customer is not only the person
who buy the finished vehicle but also the next team member in the production process.
1. Describe the overall Manufacturing Process in Toyota.

2. Besides consumer, who else are the consumers of Toyota Products?

3. Where are the Manufacturing Site is located and how wide is the area?
• The manufacturing site of Toyota Motor Manufacturing Kentucky or TMMK is located in
Georgetown, Kentucky, United States. The site covers 7.5 million square feet of floor space
with the equivalent of 156 football fields on the roof.

4. What do you observe in the process of building the body shell of Toyota cars?

5. What are the 8 Processes of Painting Toyota cars?

1. Cleaning the Body Shell.
2. ED or Electrual Deposition, An electronically charge primer that permanently bond to the shell
after the body shell of the vehicle goes to a series of rinses then has to bake into 500 degrees.
3. Dry sand and Sealed, Team members
4. Anti Chip, coating is applied to the bottom of the vehicle.
5. Primer Applied, after the primer applied the body shell bake again more than 250 degrees.
6. Wet Sand, this is the final preparation before applying the paint with the Team members

6. Robotics and high technology is being opinion regarding the use of technology in Production
Process?

7. What is the Importance of using both manpower and technology in Manufacturing Process?
8. Give your insights about how our local manufacturers improve their Production Process.

9. Cite some local manufacturers or Filipino Companies that you think are using effective
Manufacturing Process.