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Toyota Production Documentary - Toyota Manufacturing Production and Assembly at Toyota Factory

[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 team MK 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 Tim and Kay's 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 dyes

come to stamping a shop that covers

about 700,000 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 of

our vehicles once stamping begins to

make the 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 at

CMM k 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 and Kay 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 the presses 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 a team MK 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 the 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 Don 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 are a component like a

body show 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 electro deposition

is an electronically charged primary

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 the 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

at 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 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 TM MK plastics ships about

1,000 service parts each day we 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 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 arrive from our suppliers

constantly throughout the day

orchestrated by our production control

department using our just-in-time system

to minimize inventories and for 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 adding 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

assistant 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 and 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 parts 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 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 powertrain shop

powertrain 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 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 are 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 seeds and

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 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 on quality assurance tests

to check for everything from water leaks

to audio system functionality

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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