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| How the New System Started
When the Flexible Body Line (FBL) was developed in 1985 for use on mass production lines, it was considered to have enough flexibility to be compatible with the Toyota Production Method. It also won high marks for its advanced technology and innovative characteristics. However, in a period of 15 years since then, the company has expanded its overseas production facilities and there were many changes in management and social environment. As a result, we have come to need a more flexible line, one that is compatible with both low-volume and mass production, for use around the globe. In order to come up with a suitable concept for a more advanced line, we started by developing a system suitable for low-volume production, instead of one for mass production. The first step took place in 1996, when trials were conducted at a new plant in Vietnam, where production volume was extremely low and many tasks were performed manually. Then, in an attempt to utilize the line concept tested at the Vietnam plant for mass production, we introduced it to the Prius production line in 1997 as the second step. Although this line was also low-volume production line, we automated it by using robots in consideration of Japan's labor costs. The culmination of these steps took place in 1998 at the Takaoka plant where we introduced a fully-fledged line for mass producing the Vitz as the third step. This final step marked the completion of a Global New Body Line (GBL) that was compatible with our production facilities worldwide.
Certainly, we achieved one of the best body production systems in the world, but it would be fatal to get self-satisfied about it. I believe we need to keep on creating and making greater leaps. Development Concept We aimed at creating a production line that would ensure flexibility, so that Toyota production facilities around the world could easily add/switch new models or ramp up production of existing models within a short period while ensuring the top quality traditionally associated with the Toyota brand. We developed the inside locator jigs based on the concept of making manual operation easier, while in mass production, operations would be replaced by robots. The idea was if the tasks were easy for people to do, then the efficiency of the robots would also rise. By allowing the choice of either people or robots depending upon profitability, the line would offer the flexibility to handle everything from low-volume to mass production.
Anyone Can Operate It Development of the inside locator jigs has made it possible to perform multi-model production by simply changing a jig on the line, whereas it used to require 50 jigs in circulation. As a result, we can instantaneously deal with changes in model mix to suit demand fluctuations. At the same time, the reduced number of jigs needed and the downsized lines have brought about significant reductions in investment and space. With the new line, it is easier to maintain quality control because only one jig is present. In addition, there were reductions in the number of specialized devices with only one application, which were replaced by multi-application robots. As a result, anyone, anywhere in the world, can operate any process equipment by simply memorizing the operation of the robot.
People- and Earth-Friendly Production Line The term "body plant" conjures up a dark, dirty image. But by getting rid of the catwalks and conveyor safety nets behind this image, the result was a bright line with natural light. This became possible by miniaturizing the devices that used to be installed on the catwalks and making them floor mounted. In addition, by making barrier free, the line maintenance operation was made easy and safe. Streamlining the equipment and using natural lighting resulted in a reduction in lighting equipment, which greatly reduced power consumption, achieving energy savings and a 50% cut in CO2 emissions.
Digital Engineering Creation of a digital factory has led to a substantially shorter line development period. This was made possible because we were able to perform on-screen simulation of line systems with 3D solid data, including the feasibility of multi-model production, ease of work and maintenability. Simulation to ensure quality, such as body accuracy, welding quality and process capability, was also implemented on-screen. With the digital factory in place for all individual production lines worldwide, we can deal with line changes to accommodate new model launches by simply inputting new data. Even overseas lines can be operated from Japan as if we were there. Also, due to the use of visual maintenance and operating manuals, anyone, anywhere can see and understand them.
Boosting the Line Operating Efficiency to 98%
I was in charge of boosting the operating rates of the Vitz line, the world's first GBL for mass production, the FunCargo line, the second GBL, and the Carolla line which became a model for overseas deployment. In the initial phase, many problems cropped up that resulted in line stoppage and required repeated trial-and-error work every day to fix. On one particular day, Mr. Eiji Toyoda, Honorary Advisor to Toyota, visited the workshop as part of an executive inspection team and said to me, "Young man, you're part of that equipment." This was just the encouragement I needed to solve the problems and the line is now operating at 98% efficiency. As for maintenance, even a new operator can provide backup if the malfunction is not that serious. This is because the operating panel for equipment control incorporates procedural data for repairing problems. At present, we are working to make backup possible even when problems occur at other plants by visualizing text information and sharing it with each plant.
Well-Timed Planning Keyed to New Car Demand
Project Planning & Management Division covers the progress of preparations for the development and production of new vehicles at Toyota production facilities throughout the world. GBL is a worthy successor to the conventional FBL because GBL can still eliminate the line shutdowns due to the switch to or launch of new models and flexibly accommodate additions to and changes in production facilities. Furthermore, it can handle the launch of new vehicle production according to sales forecasts with only short lead times for production preparations and minimal investment because it is a revolutionary system that cuts the need for specialized jigs from 50 units to one. In the past, for example, it was difficult to respond promptly to unforeseen changes, such as big changes in production ratios between the five- and three-door Vitz models just before the start of production or the abrupt addition of the Corolla production destined for Europe and North America, to the Takaoka Plant. GBL enables us to conduct dynamic production planning, which allows the company to get cars faster to customers.
The GBL in Place in Most Overseas Mass-Production Lines
The biggest feature of GBL is that it can accommodate low-volume production, which FBL wasn't able to do. Truly a revolutionary body line, it is so flexible that it can handle everything from mass production in Japan, North America, and Europe to low-volume production in Asia and Africa. To achieve this, all jigs worldwide conform to the same specs, large jig conveyance systems have been simplified, and the entire system has been streamlined. Since its introduction in 1996 in Vietnam to produce the Camry, its use has spread to Vitz and Prius production in Japan and overseas. In order to enhance the line's reliability to facilitate application worldwide, we analyze a wide range of malfunctions and propose solutions. Hundreds of solutions have been proposed so far. Our goal is to make the line easily operable by anyone at any facility anywhere in the world. This is why we have simplified and standardized the control circuits in-house, standardized them, unified equipment types, and configured the control system so that it can immediately identify the section where a malfunction has taken place. At present, switching to GBL has been almost completed at TMMK, TMUK and TMMC.
To see the "Global New Body Line Deployed Worldwide Map", please click here. |
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