Toyota Production Documentary Toyota Manufacturing Production and Assembly at Toyota Factory

Summary

The script offers an in-depth look at Toyota Motor Manufacturing Kentucky (TMMK), showcasing the plant's vast 7.5 million square feet facility. It details the meticulous Toyota Production System, emphasizing quality, safety, and efficiency. From die manufacturing to stamping, body weld, paint, and assembly, the script highlights the plant's advanced technology and commitment to environmental stewardship. The narrative captures the transformation of raw materials into high-quality American-made Toyota vehicles, reflecting the company's dedication to craftsmanship and innovation.

Takeaways

• 🏭 Toyota Motor Manufacturing Kentucky (TMMK) is a state-of-the-art facility that embodies the Toyota Production System, focusing on quality, safety, and efficiency in vehicle manufacturing.
• 🚗 The plant is expansive, covering an area equivalent to 156 football fields, and is one of the most complete vehicle manufacturing plants globally.
• 🛠️ Production starts with die manufacturing, using advanced technology like computer-controlled lasers and hand grinding tools to ensure precision within two hundredths of a millimeter.
• 🔩 The stamping shop is massive, covering 700,000 square feet, and uses over 30 presses to shape nearly 300 sheet metal parts needed for each vehicle.
• ♻️ Sustainability is key at TMMK, with an emphasis on recycling and reusing materials, including metal scraps from the stamping process.
• 🤖 The body weld shop is highly automated, with 700 robots working alongside team members to assemble vehicle bodies, showcasing a blend of technology and craftsmanship.
• 🖼️ The paint shop is meticulous, taking over 10 hours to apply a vehicle's color, with a strong focus on maintaining a dust-free environment to ensure a flawless finish.
• 🔧 The powertrain shop is responsible for building engines on-site, with a production capacity of over 2,000 engines a day, demonstrating in-house expertise and efficiency.
• 🏗️ The assembly process is detailed and methodical, with separate lines for trim, chassis, and final assembly, each contributing to the vehicle's completion.
• 🔍 Quality control is paramount, with multiple checkpoints throughout the production process to ensure each vehicle meets Toyota's high standards before being shipped to dealers.

Q & A

What is the significance of the location where Toyota Motor Manufacturing Kentucky (TMMK) is situated?

TMMK is located in Kentucky, an area known for its bluegrass pastures, which is symbolically contrasted with the 'horsepower' of the high-quality vehicles they manufacture.

How does TMMK integrate the Toyota Production System (TPS) into its operations?

TMMK implements TPS through quality, safety, and efficiency measures, with each team member acting as an inspector to ensure no defects are passed on in the production process.

What is the size of the TMMK facility and how does it compare to other manufacturing plants?

TMMK covers about seven and a half million square feet, which is equivalent to approximately 156 football fields under roof, making it one of the most complete vehicle manufacturing plants in the world.

What technologies and tools are used in the die manufacturing process at TMMK?

Die manufacturing at TMMK utilizes computer-controlled laser technology and hand grinding tools to bring the designers' plans to life with quality measured within two hundredths of a millimeter.

How does the stamping process work at TMMK and what is its significance?

The stamping process at TMMK involves loading dies into presses to shape nearly 300 sheet metal parts needed for each vehicle. This process is significant as it shapes the fundamental structure of the vehicle bodies.

What measures does TMMK take to ensure the quality of its vehicles throughout the production process?

TMMK ensures quality by conducting multiple checks throughout the production process, with every team member acting as an inspector, and by implementing a just-in-time system to minimize defects.

How does TMMK's paint process contribute to environmental stewardship?

TMMK's paint process includes the use of a water-based system that allows for quick color changes with minimal waste, and a reclamation system that reduces overspray and the use of harsh chemicals.

What is the role of the powertrain shop in TMMK's vehicle production?

The powertrain shop at TMMK is responsible for building the vehicle's engines, with the capability to produce more than 2,000 engines a day on-site, including both four and six-cylinder engines.

How does TMMK's assembly process体现了 the principles of the Toyota Production System?

The assembly process at TMMK体现了 the Toyota Production System principles through just-in-time delivery of parts, the use of andon cords for quality control, and the implementation of Kaizen for continuous improvement, such as the removal of doors from the assembly line to improve efficiency.

What is the purpose of the rumble strips and roll drum tests during the final quality checks at TMMK?

Rumble strips and roll drum tests are used to expose any rattles, unacceptable noises, and to ensure proper gear shifting and vehicle functionality before the vehicles are approved for shipment.

How does TMMK ensure that the vehicles meet Toyota's high standards before they are shipped to dealers?

TMMK ensures high standards through a comprehensive final inspection process, which includes a detailed visual and functional inspection, as well as random selection of vehicles for further testing at the audit lab and test track.

Outlines

00:00

🏭 Introduction to Toyota Manufacturing Kentucky

The script introduces Toyota Motor Manufacturing Kentucky (TMMK), highlighting the combination of traditional craftsmanship and modern technology in producing high-quality American-made vehicles. The facility, spanning over seven and a half million square feet, is one of the world's most comprehensive vehicle manufacturing plants. The production process begins with die manufacturing, utilizing advanced laser technology and hand tools to achieve precision within two hundredths of a millimeter. The dies are then used in a stamping shop, which is equipped with over 30 presses to create nearly 300 sheet metal parts for each vehicle. The plant emphasizes quality control at every stage, with team members acting as inspectors to ensure no defects are passed along. Additionally, the script mentions the plant's commitment to environmental stewardship through recycling and efficient material use.

05:00

🔩 The Stamping and Body Weld Processes

This section delves into the stamping process, where steel coils are transformed into vehicle parts. Team members use remote-controlled cranes to move the heavy steel coils, which are then processed through blanking machines at a rate of 80 strokes per minute under 800 tons of force. The script describes the storage and quality checks before the blanks are moved to the press lines. The body weld department is highlighted as a highly automated area, with over 700 robots working alongside team members to assemble the vehicle's body shell. The process involves multiple stages, including underbody, main framing, and body shell lines, where various parts like doors, hoods, and fenders are attached. The script also mentions the production of replacement parts for at least a decade after a model's production ends, showcasing Toyota's commitment to customer service.

10:02

🎨 The Paint Shop and Powertrain Production

The script describes the meticulous paint process, which takes over ten hours and involves eight distinct steps to ensure a high-quality finish. It starts with cleaning the body shell and proceeds through various stages, including phosphate coating, primer application, and baking at high temperatures. The paint shop also employs robots that use a water-based system to minimize waste and environmental impact. In parallel, the powertrain shop is detailed, where engines are assembled with precision. The process includes short block sub-assembly, lower assembly, and final production stages, with quality checks and tests to ensure engine performance. The engines are then sent to a shipping route for just-in-time delivery to the assembly line.

15:05

🔩 Assembly Line and Just-in-Time Inventory System

The script focuses on the assembly process, which is divided into trim, chassis, and final lines. The trim line installs components such as wiring harnesses, onboard computers, and padding. The just-in-time inventory system is emphasized, with parts being delivered line-side as needed. The script also discusses the installation of the vehicle identification number (VIN) and the use of Kaizen, Toyota's philosophy of continuous improvement, to enhance safety, ergonomics, and productivity. The chassis line is where the engine, axles, and other undercarriage components are installed, while the final line sees the completion of the vehicle with the installation of seats, doors, and other exterior parts.

20:08

🚗 Final Assembly and Quality Control

This section covers the final stages of assembly, including the installation of the instrument panel, rear struts, and axles. The use of assist devices to ensure quality and safety is highlighted. The script also describes the installation of the vehicle's gear shift, taillights, and emblems. The final line sees the completion of the vehicle with the installation of the windshield, rear window, and other essential components. The just-in-time delivery of seats from a local supplier is mentioned, showcasing the efficiency of Toyota's supply chain. The script concludes with the vehicle's first gasoline fill-up, a thorough inspection under bright lights, and a series of tests on a roll drum and water shower to ensure quality and functionality.

25:10

🚗 Final Inspection and Delivery

The script concludes with the final inspection and delivery process. Vehicles undergo a rigorous quality control check, including a drive over rumble strips to detect any rattles or noises, and a test on a roll drum to verify gear shifting. They are also subjected to a water test to check for leaks. The airbag system is initialized, and randomly selected vehicles are taken to an audit lab and test track for further evaluation. The script emphasizes Toyota's commitment to quality, with every aspect of the vehicle inspected to ensure it meets high standards before being shipped to dealers across North America and the world.

Keywords

💡Toyota Production System

The Toyota Production System (TPS) is a set of management philosophies and business practices that have been widely adopted by many organizations worldwide. It is known for its focus on quality, safety, and efficiency. In the context of the video, TPS is evident in the meticulous attention to detail and continuous improvement throughout the manufacturing process at Toyota Motor Manufacturing Kentucky. The script mentions that team members put TPS principles into action, ensuring high standards of quality in American-made vehicles.

💡Quality Control

Quality control refers to the process of ensuring that products meet the required quality standards. In the video, quality control is a recurring theme, with multiple checkpoints throughout the manufacturing process to ensure each vehicle meets Toyota's high standards. The script describes how every team member is an inspector, inspecting the product to prevent defects from being passed on to the next customer or team member in the production line.

💡Just-In-Time

Just-In-Time (JIT) is a production strategy that aims to minimize waste by producing and delivering parts only as they are needed in the production process. The script illustrates this concept by mentioning how the plant typically stocks only the parts needed for about three hours of production, reducing inventory and floor space requirements. JIT is a key aspect of the Toyota Production System, as seen in the script where parts are delivered line-side as needed.

💡Kaizen

Kaizen is a Japanese term meaning 'continuous improvement.' It is a core principle of the Toyota Production System, encouraging everyone in the organization to look for ways to improve processes and products. The script provides an example of Kaizen where team members suggested removing doors from vehicles during the assembly process to reduce motion, time, and potential damage, enhancing safety, ergonomics, quality, and productivity.

💡Die Manufacturing

Die manufacturing is the process of creating metal dies, which are used in stamping to shape metal parts. The script mentions that die manufacturing starts with computer-controlled laser technology and hand grinding tools, highlighting the precision required to bring designers' plans to life. The quality of dies is measured within two hundredths of a millimeter, emphasizing the high standards of craftsmanship.

💡Stamping Shop

A stamping shop is where sheet metal is cut and shaped into parts using dies and presses. The script describes a stamping shop that covers about 700,000 square feet and uses more than 30 presses to create nearly 300 sheet metal parts needed for each vehicle. The process involves loading steel coils into blanking machines, cutting them into blanks, and then using the presses to form the vehicle parts.

💡Body Weld

Body weld refers to the process of joining together the various metal parts to form the body shell of a vehicle. The script explains that in the body weld shop, which covers about 1 million square feet, team members work with approximately 700 robots to build a complete body shell. This part of the process is highly automated and involves multiple lines, including underbody, main framing, and body shell lines, where various parts of the vehicle are assembled and welded together.

💡Paint Shop

The paint shop is where the vehicle body shell receives its paint, which is one of the vehicle's most defining qualities. The script describes a paint process that takes about ten and a half hours to complete, involving several stages such as cleaning, dipping, baking, and applying various coatings. The paint shop also emphasizes environmental stewardship by using a water-based system that minimizes paint waste and the use of harsh chemicals.

💡Powertrain Shop

The powertrain shop is where the vehicle's engine and transmission are assembled. The script mentions that Toyota Motor Manufacturing Kentucky produces more than 2,000 engines a day on-site, building both four and six-cylinder engines. The powertrain shop is responsible for machining components like camshafts, crankshafts, and cylinder blocks, and assembling them into complete engines that are tested for quality before being sent to the assembly line.

💡Assembly Line

The assembly line is the final stage of vehicle production where all the parts are combined to create a finished vehicle. The script outlines the assembly process, which includes three main operations: trim, chassis, and final. In the trim line, parts like wiring harnesses, onboard computers, and padding are installed. The chassis line focuses on installing fuel lines, brake lines, and the engine, while the final line sees the installation of the windshield, rear window, and other finishing touches. The assembly line is where the vehicle comes together and is prepared for quality testing and delivery.

Highlights

Kentuckians are harnessing a different kind of horsepower by combining Toyota's principles with local skill to build high-quality American-made vehicles.

Team members at Toyota's Kentucky plant put the Toyota Production System into action, focusing on quality, safety, and efficiency.

The plant covers about 7.5 million square feet, equivalent to 156 football fields, making it one of the world's most complete vehicle manufacturing plants.

High precision is achieved in die manufacturing, with quality measured within two hundredths of a millimeter.

The stamping shop, covering 700,000 square feet, uses giant coils of steel weighing up to 24 tons to create sheet metal parts.

Blanking machines cut steel at a rate of 80 strokes per minute with a force of nearly 800 tons.

Quality checks are an integral part of the production process, with every team member acting as an inspector.

The plant is highly automated, with over 700 robots working in the body weld shop, which covers about 1 million square feet.

The paint shop is highly controlled to prevent debris, with team members wearing lint-free clothing and passing through air blow rooms.

The paint process involves eight stages, including cleaning, priming, sealing, and applying multiple coats of paint.

The powertrain shop produces over 2,000 engines a day, with a focus on precision machining and assembly.

The plastic shop manufactures interior and exterior components using injection molding and other processes.

The assembly shop is highly automated, with robots assisting in the installation of complex components like engines and batteries.

Just-in-time manufacturing practices minimize inventory and floor space, with parts delivered as needed for production.

Quality control is stringent, with vehicles tested on a roll drum and water shower to ensure functionality and leak-free performance.

Randomly selected vehicles undergo rigorous testing at the audit lab and test track to confirm performance and comfort.

The plant's commitment to the environment includes recycling and reusing materials, and using water-based paint systems.

The Toyota Production System's philosophy of Kaizen, or continuous improvement, is practiced throughout the plant.

Transcripts

[Applause]

as the world's finest horses gallop and

play in nearby bluegrass pastures

Kentuckians are harnessing a different

kind of horsepower a Toyota Motor

Manufacturing Kentucky Kentuckians are

combining the time-tested principles of

one of the world's leading automakers

with hands-on skill and dedication to

build a high standard for quality in

american-made vehicles each day

Toledo's Kentucky team members put into

action the Toyota Production system

known across the world for its quality

safety and efficiency teaming K covers

about seven and a half million square

feet of space with the equivalent of

about one hundred and fifty six football

fields under roof this is one of the

most complete vehicle manufacturing

plants in the world

TM MKS production process starts and die

manufacturing by using everything from

computer-controlled laser technology to

hand grinding tools these team members

bring the designers plans to life with

quality measured within two hundredths

of a millimeter once complete the dies

come to stamping a shop that covers

about seven hundred thousand square feet

the dies 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 of our vehicles once stamping begins

to make nearly 300 sheet metal parts

needed for each vehicle stampings work

begins with these giant coils of steel

weighing up to 24 tons team members on

the floor moved the coils using a remote

control overhead crane the coil is

loaded into one of our four blanking

machines which straighten and clean the

metal then the machines cut the metal

into blanks the blanking machines cut

the steel at a rate of 80 strokes per

minute using a force of nearly 800 tons

the finished blanks are fed into

stackers that automatically stop at the

beginning and end of each production

process for a quality check this is one

of the many times we will check the

quality of our vehicles during the

production process every team member a

team MK is 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 buys the

finished vehicle but also the next team

member in the production process

when blanks pass inspection they're

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 MK 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

dies 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 depresses is

nearly three feet of solid concrete the

larger presses 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 our plant we 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 it seemed m'kay we have the process

down to about 10 minutes at the end of

our 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 our

body weld Department

in about two hours body weld builds a

complete body shell this shop

covers about 1 million square feet and

is the most automated part of our plan

its team members work with some 700

robots body weld is divided into four

lines underbody Rhys pot underbody

tacking main framing body and body show

here in the underbody Rhys pot line

three major sections of the underbody

come together the engine compartment the

front floor and the rear floor then the

underbody 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 on this line

next the vehicle bodies are lifted onto

the overhead conveyor and taken to the

body shell line the last line in body

weld on the body shell line 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 the 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

Team MK stops production of a model

here in paint a body shell gets what

will be one of the vehicles most

defining qualities its color

and we 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 donned 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 ten and a half hours to complete

starting when a completed body show is

pulled from body weld the pull system is

an aspect of the Toyota Production

systems just in time concept when

material or a component like a body

shell is needed it's pulled to the shop

not pushed as in many traditional

manufacturing facilities by pulling

instead of pushing we produce only what

we need when we need it and in the

amount needed painting at Toyota

involves eight basic processes but first

the body show 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 a process that itches

the body shell so primer and topcoat

will better adhere to it

next is the IDI dip the electrode

deposition is an electronically charged

primer that permanently bonds to the

shell after edie the body goes through a

series of rinses then is oven-baked at

nearly 500 degrees next in dry sand 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 process in paint

is anti chip here a coating is applied

to the bottom of our vehicles where they

will receive the most Road damage

in the next process primer is applied to

smooth out the appearance of previous

layers then the body shell is baked

again this time at more than 250 degrees

the sixth process in paint is wet sand

here the shell will get its final

preparation before painting with team

members inspecting it and removing any

last imperfections next the vehicle gets

its topcoat in one of three paint 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 lets 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

overspray that enters our reclamation

system next the painted shell is baked

again this time at around 250 degrees

for about a half an hour then the

painted body is checked for any

imperfections at the eighth and final

process final inspection they're

approved vehicles go to the selectivity

bank ready to be pulled to assembly when

needed

while the bodyshell is being welded and

painted our powertrain shop is building

the vehicles engine TM MK produces more

than 2,000 engines a day on-site we

build both four and six-cylinder engines

in this 1.2 million square foot shop

[Music]

power trains raw materials include

engine blocks and heads that come from

our suppliers team MK has more than 350

suppliers in North America over 100 of

which are located in Kentucky powertrain

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 here team members install

the crankshaft pistons and piston pin

assemblies after the engine receives a

balance shaft for vibration reduction it

moves to lower assembly the second

assembly process next 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 a Toyota Production system

judoka is our practice of stopping

production whenever a problem is

detected many of our machines will

automatically do this and our team

members can do this as well to keep any

flaws out of our products next a team

member installs the timing belt timing

cover and oil and water pumps as the

engine moves down its line team members

confirm their work and that of previous

processes in the final production stage

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 here 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 two to three 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 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

and more than four hundred 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

plastics 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

and from vendors also in the shops

injection molding area team members make

trim for the vehicles interior and

produce the manifold they injection mold

each piece then combined in 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

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

planet in Indiana and to dealers as

service parts TM MK plastics ships about

1000 service parts each day we supply

service parts for up to 21 years after

the production stops for 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 a

parts carrier for delivery to the next

process including assembly

TMM Ches assembly shops are the largest

in the plant covering nearly 2 million

square feet assembly one 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 onto the

trim line trim installs parts largely

unseen by customers like wiring

harnesses onboard computers and padding

that will keep the vehicle's interior

quiet at the beginning of this line a

team member places a manifest sheet on

each vehicle this sheet tells team

members which parts and which options to

install on each vehicle coming down the

line here the car also gets its 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 arrived from our suppliers

constantly throughout the day

orchestrated by our production control

department using our just-in-time system

to minimise inventories in floor space

the plant typically stocks on-site only

the parts needed for about three 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

they'll box some parts for a particular

vehicle together into what we call

kidding kidding 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 kidding let's team members focus

on a quality installation as the vehicle

works its way down our assembly trim

line it gets one of its most important

features its VIN or vehicle

identification number this machine is

striking 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 here a

team member installs the side curtain

airbag one of the first of up to 10

airbags that will be installed depending

on the vehicle model one of the first

Japanese words and concepts that our

team members learn at Toyota is Kaizen

it means continuous improvement and is a

hallmark of the Toyota Production system

every team member contributes to Kaizen

here is a great example of Kaizen when

Team MK began production in 1988 the

doors stayed on the vehicles throughout

the assembly process several years later

following a team ever suggestion we

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 do they chance being hurt by walking

into the doors the Kaizen also reduces

the possibility that the doors

themselves will be damaged and it lets

us 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

here windows patting locks speakers and

other components and options are

installed with the doors now at eye

level team members can complete their

work easier and safer

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 doorless vehicle continues

its assembly process on the trim line

where the hood insulation is installed

this padding helps keep engine noise in

the passenger compartment and outside of

the vehicle to an absolute minimum TM MK

builds hybrid versions of many of its

models and here 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

assist devices like this are used

throughout our plan to help keep our

team members safe in injury free

trim also installs the headliner

moonroof trim and visors hanging just

above the line near our team members is

an and on cord

our team members have a certain set

amount of time to do their jobs we call

this tack time if they have a concern or

encounter a problem that keeps them from

meeting that tech time they can pull the

end on cord and call for help

pulling the andon cord activates tunes

lights and boards the TEL team and group

leaders that they're needed and where

they'll respond and try to address the

concern without stopping the line but if

they can't do that within the tech time

they will pull the cord again and all of

production stops or if need be they'll

take the vehicle off line to make any

needed repairs next in trim the vehicle

gets the instrument panel that was made

for it in plastics when the IP left

plastics it came to the IP line another

sub assembly line here in trim here team

members install among other components

air-conditioning duct work controls

gauges to monitor speed and fuel stereo

options and the steering column once the

IP is complete an automatic guided

vehicle or AGV delivers it line side for

installation into the vehicle these

smart 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 our team members

and help ensure a quality installation

trim also installs the vehicle's axles

which are built on site by our

powertrain shop

next comes the gear shift and the rear

taillights team members on this line

also placed the Toyota and model emblems

carefully onto 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 powertrain shop

powertrain supplies the engine block to

the engine line in assembly 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 where 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 also in chassis the vehicle

gets a radiator rear speakers seatbelts

and carpet here our quality control team

member inspects the work of chassis

helping to ensure that only the best

work is shipped on the wheels and lug

nuts are installed by this machine a nut

runner it's used to ensure that all the

lug nuts are tightened to the exact

torque needed the nut runner features a

poky oak a pokey oak is a fail-safe

device that detects defects and prevents

them from being processed any further

pokey Oaks are used in conjunction with

many pieces of our equipment especially

critical processes to ensure safety and

quality at the 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 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 vehicle's windshield and

rear window glass this final line team

member is installing the center console

with the help of a floating chair called

a raku see 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 seats and ship

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 for 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

under these bright lights team members

inspect every inch of the body surface

and interior closely to make sure that

it meets Toyota's high standards and

quality at the end of this line a

quality control team member drives the

vehicle off the line and across rumble

strips these create vibrations which

will expose any rattles or unacceptable

noises the team member positions the

vehicle on the tow adjust to adjust the

steering wheel as another team member in

the pit below aligns the vehicle team

members then test the vehicles

functionality on a roll drum as the

vehicles move from zero to about 80

miles an hour

team members check for proper gear

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 installation

the vehicle's 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 unqualified

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 we inspect 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 us a film 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

[Music]

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