Kakuro Amasaka

New JIT: A new management technology principle at Toyota

Abstract A future successful global marketer must develop an excellent quality management system that impresses users and continuously provides excellent, quality products in a timely manner through corporate management. The author proposes New JIT, a new management technology principle for manufacturing in the 21st century. New JIT contains hardware and software systems as next-generation technical principles for transforming management technology into the management strategy. The hardware system consists of the Toyota Marketing System (TMS), Toyota Development System (TDS) and Toyota Production System (TPS). These are the three core elements required for establishing new management technologies in the marketing, engineering and production divisions. To improve work process, quality of all divisions concerned with development, production and sales, the author proposes Toyota Total Quality Management utilizing Science SQC (TQM-S) as the software system. The author believes that New JITs effectiveness has been demonstrated as described herein based on the authors experience at Toyota.

IMPROVING THE RELIABILITY OF BODY ASSEMBLY LINE EQUIPMENT

It is necessary to establish higher levels of equipment reliability in a short time, the market demands ever shorter lead times for the release of new models. Also, the demand for new-model cars is very strong immediately after their introduction. The conventional method for enhancing equipment reliability is by screening alone. However, this requires screening operations on production lines and so has been an obstacle to line production and prevented shortening of lead times. We are now able to dramatically enhance equipment reliability in a very short time by detecting failure modes and forecasting the number of occurrences using a scientific technique based on reliability engineering.

V-MICS, ADVANCED TPS FOR STRATEGIC PRODUCTION ADMINISTRATION: INNOVATIVE MAINTENANCE COMBINING DB AND CG

To achieve worldwide high productivity and quality assurance of global production, the authors considered the necessity of including the above with strategic application of the TPS, and clarified the Advanced TPS as the global production by manufacturing technology for the strategic administration of production facilities. Nowadays, we have established manufacturing technology by innovative maintenance of Toyota, a most advanced automotive manufacturing enterprise. Therefore, we propose the V-MICS (utilizing Visualization-Maintenance Innovated Computer System) consisting of five steps (AML-1 to AML-5). Concretely for transfer of the maintenance skill, in particular we will accomplish a procedure combining DB (database) and CG (computer graphics). With regard to the former we will construct a DB for easier accumulation of know-how for parts replacement and other jobs. As regards to the latter, we will provide the instructions to enable even a person not familiarized with machine-drawings to carry out dairy inspection. As a result, we will not only attain considerable reduction of the maintenance cost, but also realize a lot of benefits such as more improved availability when we start up the global production in the world.

A demonstrative study of a new SQC concept and procedure in the manufacturing industry

A review of the changes in the environment surrounding the manufacturing industry indicated an ever greater necessity for corporate efforts to amplify and capitalize upon the technical prowess of the engineering staff who bear the main burden of these times. In this study, we propose the establishment of a new technical method for conducting scientific SQC as a new concept and procedure that will improve the job quality of the engineering staff in each stage of the business process so as to contribute to production with excellent QCDS. We also try to evaluate and investigate its usefulness on the basis of an actual study example in Toyota.

TPS-QAS, new production quality management model: key to New JIT- Toyota's global production strategy

Recently, the authors have worked out a new management principle named New JIT based on TMS, TDS, TPS and TQM-S to strengthen Toyotas global production strategy. This paper verifies the effectiveness of the proposed Advancing TPS as the key to New JIT at Toyota. Toward enabling simultaneous production start-up (the same quality and production at optimal locations), an integrated network system that utilises QCIS (Quality Control Information System), ARIM (Availability Reliability Information Administration Monitor), AWD6P/J (Aging & Work Development 6 Project) and V-IOS (Virtual – Intelligence Operator System) by using AOL (Advanced Operator Levels) rank model, the next-generation, production quality management model TPS-QAS (Toyota Production System-Quality Assurance System) is proposed. In cases of application, we take up examples for systematic development of quality assurance technologies to test the validity of TPS-QAS as a new global production quality management system at Toyota.

Development of a robot control method for curved seal extrusion for high productivity in an advanced Toyota production system

Recent Japanese enterprises have been promoting global production to realize uniform quality worldwide and production at optimal locations for survival amid severe competition. The authors considered the necessity of including the above method in the strategic application of the Toyota production system (TPS), and clarified Advanced TPS as the global production by manufacturing technology. In the future, reformation of the production workshops transformed by robotics and IT will be necessary in order to keep the same quality worldwide and production at optimum locations. Thus manufacturing technology had to be improved for mass production by developing the latest robot control methods. So far, the authors have established a robot control method for global production called RCM-EPC. RCM-EPC contains a three-core robot control method with (i) locus and speed control of the external point (-LSC), (ii) simulation for optimizing the operation position (-SOP) and (iii) constant speed control for robot movement (-CSC). Furthermore robots are applied to several applications in order to improve productivity and achieve a high-quality appearance. In particular, the authors here introduce an up-to-date glass-integrated curved seal extrusion (CSE), which is a new technology for use in manufacturing: the automobile-window mole as an example for Toyota – one of the most advanced automotive manufacturing enterprises in the world. With the demonstration of a 50% reduction in manufacturing costs using Advanced TPS, the authors have achieved high productivity and quality assurance in global production.

A study on “science SQC” by utilizing “management SQC” – A demonstrative study on a new SQC concept and procedure in the manufacturing industry

Abstract Looking at changes in the environment surrounding the manufacturing industry, corporate efforts to foster the development capabilities of engineers for new products are again being called for. This study outlines “science SQC” by utilizing “management SQC” as a new SQC concept and procedure in the manufacturing industry for improving the job quality of engineers and managers in each stage of the manufacturing business and process with excellent QCD, and introduces application examples at Toyota.

The robot reliability design and improvement method and the advanced Toyota production system

Purpose – To demonstrate the theory and effectiveness of reliability‐improvement countermeasures for line equipment, specifically industrial robots for automotive production engineering.Design/methodology/approach – Suggests an efficient method of life‐cycle maintenance. The defects of industrial robots are analysed using Weibull analysis.Findings – From the analysis, a strategy of countermeasures is framed for component screening, reliability design and lifetime estimation.Originality/value – This method has been implemented worldwide in Toyotas factories, and has produced a better operating life cycle for industrial robots.

The Promotion of the New Statistical Quality Control Internal Education at Toyota Motor: A Proposal of 'Science Statistical Quality Control' for Improving the Principle of Total Quality Management

SUMMARY Recently, it has been of importance to challenge the manufacturing production demands for the 21st century. This report proposes a new statistical quality control (SQC) concept, ‘science SQC’ as a demonstrative-scientific method, which enables us to improve the principle of total quality management systematically. The objective of this approach is to indicate the application of a New SQC Internal Education through implementing ‘Science SQC’, which leads to promoting organically the business process quality. The performance of the proposed method and the results are given through studies and practices at a manufacturing company—the Toyota Motor Corp.

Creation of automobile exterior color design approach model “A-ACAM”

The quality of a cars exterior color has become a major aesthetic factor (preference) influencing the car buying process. Thus, for this study, the authors have created “A-ACAM” (Automobile Exterior Color Design Approach Model) and the models effectiveness has been verified. In creating the model, the authors utilized information from their own research, entitled “Kansei engineering in automobile”. They first determined the four elements most desired by young people when choosing exterior colors (classy, luxurious, dignified, and sporty). Next, they determined the six elements of color (hue, luminosity, intensity, shine, opacity, and graininess) that influence young buyers the most. Correspondence analysis was then applied with the aid of statistical science (multivariate analysis) in order to correlate the young peoples preferences with the color elements, enabling the authors to determine the degree of influence of each of the color elements. Based on these findings, the model has subsequently been applied in exterior color development (paints and painting methods), demonstrating significant results.