Streamlining Manufacturing through Skill & Technology: Showcasing Toyota's On-Site Production Methods
Toyota Streamlines Production with Digitalization and Lean Manufacturing
Toyota Motor Corporation is revolutionizing its manufacturing processes, aiming to halve the number of manufacturing steps through a combination of advanced digitalization and Lean manufacturing principles. This initiative, showcased at the Monozukuri Workshop held in September, is designed to minimize waste, optimize processes, and enhance efficiency by adopting smart technologies and integrated digital management systems in manufacturing workflows [1].
Key advanced technologies involved include:
- Digital management systems for real-time asset, maintenance, and quality management, replacing traditional manual methods like logbooks and printed records. This digital transformation aligns with Lean principles and supports sustainable development goals by increasing operational efficiency and accuracy [1].
- Emphasis on cross-disciplinary group consensus and problem-solving approaches drawn from Japanese manufacturing culture. These practices ensure thorough understanding and innovative, simple solutions that improve workflows and prevent complexity and rework during implementation [2].
While specific detailed technologies in Toyota's Monozukuri Workshop beyond digital management are not explicitly outlined in the search results, it is consistent with Toyota's known emphasis on the Toyota Production System (TPS), which integrates Just-In-Time (JIT) production, Autonomous Maintenance, Kaizen continuous improvement, and Automation with human touch (Jidoka) [5].
One of the most significant advancements is the implementation of self-propelled assembly lines, which have been trialed in the production of the NOAH and Voxy models. These lines use vehicle control and sensor technologies developed for autonomous driving, allowing vehicles to move along the set route at 0.36 km/h. This innovation improves work efficiency by allowing seats and other components to be mounted before the roof and side panels are attached [3].
Moreover, Toyota is developing a popular version of its next-generation battery with a supersized bipolar structure. The all-solid-state battery production process requires high-speed, high-precision stacking to ensure performance. To address the challenge of maintaining zero relative velocity between pallets carrying and receiving batteries, Toyota has developed equipment that solves this problem [4].
Toyota's Chief Production Officer, Kazuaki Shingo, shares a vision of using digital technology to eliminate barriers between development and production. The company is also focusing on the Motomachi Plant, a multi-pathway mass production plant where different types of vehicles, including hybrids, battery electric vehicles, and fuel cell electric vehicles, are built. The plant is undergoing a transformation with a new modular structure for BEVs, dividing the underbody into three sections: front, center, and rear [6].
The Teiho Plant, a startup hub that provides equipment and production methods for carmaking, is another key component of Toyota's manufacturing transformation. The company is also minimizing the need for heavy transport machinery and responding more flexibly to change by simplifying and automating operations for both plant equipment and mass-produced vehicles [7].
In the casting plant, Myochi, expert craftsmanship is combined with innovative technology to produce engine parts for motorsports. Toyota is also developing all-solid-state batteries, which offer faster charging and longer range, with the aim of commercialization in 2027-2028 [8].
In conclusion, Toyota's Monozukuri Workshop is a testament to the company's commitment to innovation and efficiency. By leveraging a combination of digitalized workshop management, Lean methodology, collaborative problem-solving, and TPS principles, Toyota is aiming to halve manufacturing processes, enhance efficiency, and achieve high-quality outputs through advanced yet pragmatic technologies and methods [1][2][5].
[1] Toyota Global. (2021, September 28). Toyota's Monozukuri Workshop 2021. Retrieved from https://global.toyota/en/newsroom/corporate/33534402.html [2] The Monozukuri Workshop. (2021, September 28). Toyota Motor Corporation. Retrieved from https://global.toyota/en/newsroom/corporate/33534402.html [3] Toyota. (2021, September 28). Toyota's Monozukuri Workshop 2021. Retrieved from https://global.toyota/en/newsroom/corporate/33534402.html [4] Toyota. (2021, September 28). Toyota's Monozukuri Workshop 2021. Retrieved from https://global.toyota/en/newsroom/corporate/33534402.html [5] Liker, J. K. (2004). The Toyota Way. McGraw-Hill Education. [6] Toyota. (2021, September 28). Toyota's Monozukuri Workshop 2021. Retrieved from https://global.toyota/en/newsroom/corporate/33534402.html [7] Toyota. (2021, September 28). Toyota's Monozukuri Workshop 2021. Retrieved from https://global.toyota/en/newsroom/corporate/33534402.html [8] Toyota. (2021, September 28). Toyota's Monozukuri Workshop 2021. Retrieved from https://global.toyota/en/newsroom/corporate/33534402.html
- Toyota's commitment to innovation extends beyond manufacturing, as they are also investing in finance and business through data-and-cloud-computing technology to streamline asset, maintenance, and quality management.
- Beyond digital management, Toyota is exploring technology advancements in investment areas like self-propelled assembly lines, all-solid-state batteries, and modular structures for electric vehicles, aimed at enhancing work efficiency and embracing sustainable development.
- As technology plays a crucial role in Toyota's manufacturing transformation, they are aware of the need to establish partnerships with finance and investing institutions to secure funding for their ongoing research and development in data-and-cloud-computing, technology, and the manufacturing industry.
