 Name: Ali Amjad

 Seat no: B20542061

 Class: BBA-V (A)

Toyota
Introduction:

Toyota is one of the largest automobile manufacturers in the world. The

company was founded in 1933 Kiichiro Toyoda and incorporated in
1937. Toyota produces around 10 million cars each year and is the
biggest car manufacturer in the world. Their cars are sold in nearly every
continent in the world like Asia, North America and Europe. Note able
brands of Toyota are Corolla, Prius, Camry, Lexus and Land Cruiser.

Operations Management:

Several operational processes must be performed on a periodic basis to

guarantee that the physical supply chain is operating efficiently and
effectively. These processes integrate and synchronize the operational
processes with the physical processes to ensure a lean supply chain.
Transformation Process

Parts are produced by suppliers and transported by inbound logistics to

the assembly plant. At the assembly plant, the vehicle begins in the body
shop, moves to the paint shop, then to assembly, and finally to
inspection. Once the vehicle is produced, it is transported to the
dealerships via outbound logistics.
Operations Flow:
Stamping Shop: The stamping shop is where the body parts for a
vehicle are stamped out of huge coils of steel. Large stamping presses
are arranged in a row connected by conveyors. At the start of one row of
presses, sheets of steel are cut from the coil and fed into the first press.
Body Shop: The body shop is where a vehicle is born—where it gets
its identity. At body start, each vehicle gets a unique body number and is
assigned a Vehicle Identification Number (VIN).
Paint Shop: Color is applied to the vehicle at the paint shop. The shop
consists of multiple paint booths that use robots to spray-paint the
bodyshells coming from the body shop. As the vehicle body shells enter
the paint shop, they are dipped in a solution that covers the body with a
protective coating.
Assembly Shop: The assembly shop is the most labor-intensive
shop. Most of the parts are installed by hand by team members working
in small teams. Each team is responsible for the work performed during
one process cycle at one workstation.
Inspection: After the vehicle is completed and comes off the main
assembly line, it is driven to the inspection line. The primary purpose of
this inspection is to conduct functionality tests on such components as
the engine, transmission, brakes, and air bags.
Sales Line: The point at which a vehicle’s ownership is transferred
from the manufacturing division to the sales division is the sales line.
Supply Chain Model:
Suppliers: Suppliers provide thousands of parts and components that
go into the vehicle. These parts and components are received via the
inbound logistics network from hundreds of tier 1 suppliers.

Inbound Logistics: After parts are produced by the suppliers, they

are shipped to the assembly plants. The process to ship these parts from
the many suppliers to each assembly plant is referred to as “inbound
logistics

Production: Vehicles are produced at the final assembly plant from

the parts provided by hundreds of suppliers. A typical assembly plant
will have one or more separate lines on which vehicles are assembled.
The plant is subdivided into shops. The vehicle is born in the body shop
where the frame and body are formed.

Outbound Logistics: Vehicles that are produced at an assembly

plant must be transported to each dealer. This process is commonly
referred to as “outbound logistics.”

Dealers: Dealers play a key role in the supply chain because they are
the face of Toyota to the customer. They are responsible for selling the
vehicles produced by the manufacturer to the retail customers.
Distribution:
Overseas parts arriving from Japan are shipped via vessel to a port and
then transported by railcar to the assembly plant. Once the railcar arrives
at the assembly plant rail yard, the container is offloaded onto a truck
and driven to the assembly dock.
Materials Suppliers:
Toyota manages a vast network of more than 200 suppliers for their
parts. Some notable parts are mentioned below:

Tires: Dunlop Goodyear is one of the major tire suppliers for Toyota
cars.

Vehicle Body: Central Motor Co. manufactures car chassis for

Toyota.

Interior Parts: Johnson Controls K.K are bound to provide Car seats
and interior panels

Audio: Pioneer Corporation is tasked with supply of car electronics

and audio equipment.

Battery: Furukawa Battery Co. provides lead, and alkaline storage

batteries.

Brakes: Bosch Corporation provides brake equipment.

Vehicle Engine: Daihatsu Motor Co Ltd. Provides Toyota with their

power trains.
Paints: Nippon paints supplies Toyota with body paint colors.

Steering: TRW Automotive Japan are the supplier for steering and
suspension parts.

Cycle View Process:

Each cycle occurs at the interface between two successive stages of the
supply chain. A cycle view of the supply chain is very useful when
considering operational decisions. It clearly specifies the roles and
responsibilities of each member of the supply chain
 Customer Order Cycle:
The process starts between the customer and dealership, once the
customer books their order.

Customer arrives at the dealership and books The dealership will call the customer to receive
their desired Toyota car. their booked car and then the ownership will be
transferred to them

Order Placement Order Delivery

Order Confirmation Order Fulfilment

After that, the assembly plant starts order

Once the order is confirmed, the dealership than manufacturing and once it’s completed, then the
communicates the demand to assembly plant car will be sent to dealership. Assembly plant will
call suppliers to replenish the inventory