Toyota Production System

A Production System that is steeped in the “completely eliminate all waste” philosophy, which comes from the product life cycle of a product, is constantly looking for the most efficient methods to follow this premise. The Toyota Motor Corporation Car Production System is a means of “doing things” that is sometimes referred to as an “efficient production system” or a “Just-in-Time (JIT) system,” being known and studied in Worldwide. This Production Control System was established based on years of continuous improvement and innovation, with the objective of “making cars according to customers’ request in the shortest and most efficient possible time, in order to deliver the cars as quickly as possible”. The Toyota Production System (TPS) was established based on two concepts: the first is called “jidoka” (which is easily explained as a “car with human touch”) which means when a problem occurs, the production line stops immediately, preventing defects in products; the second is the “Just-in-Time” concept in which each assembly-line process produces only what is strictly necessary in product flow. Based on the jidoka philosophy and Just-in-Time, TPS can produce one car at a time with efficiency and speed, with all the quality, that satisfies all the requirements that the customer  also wants car cover for outside protection.

“Quality has to be built during the production process!”

If the equipment is not working or some part of the car is defective and is detected, the process automatically stops, stopping production by the employees who will solve the problem. In order for the Just-in-Time System to work, all parts of the car that are produced must meet the quality standards. This is achieved through the jidoka. Jidoka means stopping the machine when it completes the normal process. It also means, if a problem of equipment or quality arises, the machine detects the problem and stops, preventing the production of defective products. As a result, only products that meet quality levels pass through assembly line processes. A machine stops automatically when the process is complete or when a problem is detected and communicated via “andon” (problem display board), operators can continue working on other machines, as well as easily identify the problem so that it is not repeated . This means that each operator can be responsible for multiple machines, not neglecting productivity and making time safer, while making the necessary improvements in the rest of the process.

“Produce only what is strictly necessary, when it is necessary and in the necessary quantity!” Quality production, with an efficient system, eliminating waste, are the necessary requirements in a production line. In order to deliver a car to the Customer in the shortest possible time, the car must be produced as efficiently as possible in the shortest possible time. Production based on the following assumptions: When ordering a car is received, the production start order must be issued to begin the process as soon as possible. The assembly line must be stocked with the required number of parts required so that any type of ordered car can be assembled. The assembly line should replace the used parts, recovering the same number of parts from the process of “producing parts”, that is, from the previous process. The previous process should be stocked with small quantities of all kinds of parts and produce only the number of parts that have been recovered by a worker, from the next process.

Globalization & Factory Location

“Made by TOYOTA” – Assuring quality on a global level.

Since 1957, when the Toyota Crown was Toyota’s first car to be exported to the United States, Toyota has extended the scope of car sales worldwide. For more than 50 years, Toyota cars have found their way in more than 170 countries and regions around the world. As exports continued to develop, Toyota chose to locate its Factories, in accordance with the policy of “producing cars where there is demand.” At present, there are 51 factories in 26 different countries and regions. In addition, there are R & D projects and plants in 9 locations, showing that “from development and design to production, as well as sales and services, Toyota has achieved a consistent globalization and localization of its products.”

Illustration of the Toyota Production System

Among the obstacles overcome by the Brand in this globalization of production, the most important is quality assurance, which requires that “no matter where the Toyota cars are produced, they must have the same level of quality.” Toyota does not label cars that are “made in the USA” or “Made in Japan,” but instead chooses to tag everyone saying “Produced by TOYOTA.” This means that there is a need to disclose Toyota’s production philosophy – the “Toyota Model” – in all Factories abroad. In addition, this reference is important to minimize the support coming from Japan, allowing each of the sites to become self-sufficient. As an example, the Toyota Factory, which has recently commenced production in Texas, has made a maximized use of the know-how of the Toyota Factory in Kentucky, which has been built over the past 20 years. Toyota believes that the way to achieve quality assurance and to spread the “Toyota Way” philosophy is to educate people. In 2003, the Global Production Center (GPC) was established within the Motomachi Factory located in Toyota City. In addition, in 2006, Toyota established regional GPCS in the United States, United Kingdom and Thailand to perform corresponding activities in North America, Europe and Asia Pacific.

In order to deliver the vehicles as swiftly as possible. The Toyota Production System (TPS) was established based on two concepts: “jidoka” (which can be loosely translated as “automation with a human touch”), as when a problem occurs, the equipment stops immediately, preventing defective products from being produced; and the “Just-in-Time” concept, in which each process produces only what is needed for the next process in a continuous flow.TPS and its approach to cost reduction are the wellsprings of competitive strength and unique advantages for Toyota. Thoroughly honing these strengths is essential for Toyota’s future survival. We will use these initiatives and develop our human resources to make ever-better cars that will be cherished by customers.First, human engineers meticulously build each new line component by hand to exacting standards, then, through incremental kaizen (continuous improvement), steadily simplify its operations. Eventually, the value added by the line’s human operators disappears, meaning any operator can use the line to produce the same result. Through the repetition of this process, machinery becomes simpler and less expensive, while maintenance becomes less time consuming and less costly, enabling the creation of simple, slim, flexible lines that are adaptable to fluctuations in production volume. The work done by hand in this process is the bedrock of engineering skill.

Rather, they evolve as we transfer our skills and craftsmanship to them. In other words, craftsmanship is achieved by learning the basic principles of manufacturing through manual work, then applying them on the factory floor to steadily make improvements. This cycle of improvement in both human skills and technologies is the essence of Toyota’s jidoka. Advancing jidoka in this way helps to reinforce both our manufacturing competitiveness and human resource development. Human wisdom and ingenuity are indispensable to delivering ever-better cars to customers. Going forward, we will maintain our steadfast dedication to constantly developing human resources who can think independently and implement kaizen. The Toyota Production System (TPS), which is based on the philosophy of the complete elimination of all waste in pursuit of the most efficient methods, has roots tracing back to Sakichi Toyoda’s automatic loom. Motor Corporation. Waste can manifest as excess inventory, extraneous processing steps, and defective products, among other instances.The result was the Just-in-Time method. Via the philosophies of “Daily Improvements” and “Good Thinking, Good Products, TPS has evolved into a world-renowned production system. Even today, all Toyota production divisions are making improvements to TPS day-and-night to ensure its continued evolution.

About Toyota Corolla

The three GLi configurations bring the same 1.8 16V flex engine with aluminum block of the previous model, generating 144 hp of power and 18.6 kgfm of torque with ethanol. With gasoline, the numbers are respectively 139 hp and 17.7 kgfm. This propulsor can be accompanied by a six-speed manual transmission or a CVT automatic with seven-speed simulation. Already the options XEi, XRS and Altis have engine 2.0 16V flex of aluminum that develops 154 cv of power and 20,7kgfm of torque with ethanol. Respectively, with gasoline, the numbers are 143 hp and 19.4 kgfm. Here, the only exchange option is the automatic CVT.

More from Corolla

In the measurements, the sedan is now 4.62 m long, 1.8 m wide, 1.48 m high and 2.70 m wheelbase. The trunk accommodates up to 470 liters of luggage. The weight of the model varies between 1,265 kg (manual GLi) and 1,340 kg (Altis CVT). The facelift changes focus mainly on the front, with a set of restyled and sharper headlights and grille. The front optical assembly has halogen headlights in the GLi and XEi versions, and LEDs, with automatic leveling, in the XRS and Altis versions. Flashlights with daytime running lights are available from the XEi version, and all feature front LED taillights. The chrome bar in the trunk lid is thinner. The back and arrow lights are also dimmed. From the XEi version, the Corolla also gained a shark fin antenna style and 17-inch alloy wheels. In the configurations with the larger wheels, the suspension was raised by 5 mm and the electric steering box was recalibrated. Since the entry version of Corolla comes with electric steering, air conditioning, on board computer, steering column with height and depth regulation, radio with USB, power mirrors and mirrors with multifunctional steering wheel.

Past

The Toyota Corolla was born in 1966, gaining new generations in 1970, 1974, 1979, 1983 and 1987. The sedan landed in Brazil only in 1994, then in the seventh generation, imported from Japan. In August 1998 it was manufactured in Brazil. Country in Indaiatuba (SP), already in the eighth generation. In 2002 came the ninth generation, the second national, who debuted the engine 1.8 flex. In 2008 the Corolla reached the tenth generation, which added the top Altis configuration. The 11th generation introduced a completely renewed sedan, launched in March 2014, already as a 2015 line. In March 2017, the country returned to the restyling along with the return in the sports version XRS and the addition of the much desired stability control.

More from SW4

Produced in Zárate, Argentina, the new SW4 is bigger than its predecessor, with 9 cm more in length (4,79 m) and 1,5 cm in width (1,85 m). The other measures, however, decreased, with 1.5 cm less in height (1.83 m) and 0.5 cm less in wheelbase (2.74 m). The SUV also featured redesigned headlights, front grille, bumpers and taillights, plus redesigned interior with lower panel, new layout of controls inside the cabin and finish with metal details and imitating wood. Another important change is that the reduced 4×4 traction selection lever has been replaced by a knob on the center console.

Flex, SUV is offered only in the SR version, which comes with air conditioning, power steering, steering wheel with height and depth adjustments, knife-type switch, on-board computer, speed controller, console chassis, side brakes, trio electric, fog lights, front and knee airbags for driver, tow assistant, ramp start assistant, traction and stability control, rear parking sensor and multi media center with 7 “touch screen, GPS, TV Digital, DVD, rear camera, Bluetooth and USB and AUX connections. On diesel, it is offered only in the top-of-the-line SRX version, which features digital air conditioning with rear row outputs, power steering, steering wheel with height and depth settings, driver’s seat with electric adjustments, airbags with electric opening and closing, seven airbags (front, side, curtain and knee for the driver), headlights with LED daytime running lights, leather-wrapped seats, 18 “alloy wheels with 265/60 R18 tires, ramp start assist, descent assistant, traction and stability controls, rear differential lock, rearview mirrors with electric folding, isofix system for infant seats, refrigerated glove compartment, rear camera and sound system with touch screen 7 “, GPS, digital TV, DVD, MP3, Bluetooth and steering wheel controls.

Past

Developed from the Hilux pickup truck, the Hilux SW4 sports utility vehicle was initially imported from Japan. In 2005, it was brought from Argentina. The utility, which has not received any upgrades since 2008, received a rebuilt in 2012 with changes to the bodywork and new equipment. In 2016, the new generation arrived in Brazil, with visual and mechanical changes. The flex configurations returned to the catalog only in mid-2016, already as the 2017 line. In 2018, the new Diamond version was incorporated.