Process Chart In Toyota

Process chart is a traditional diagramming technique and it has three type. Toyota prefers to use a special process chart that provides the best illustration for processes made Toyota facilities. It likes worker process chart technique but it does not use defined symbols. Worker process chart is used to analyze the activities of a worker to perform a task around the facility. The process chart used at Toyota is called “unit-work form”. It includes representation of operation, job steps in a listed way, critical points related with some job step, reasons for the critical points and finally time spend while in manual work, in walking and in road to make the job step. These parts in the process charts is standardized for all Toyota facilities.

Jundate is Japanese word and it used as special term in Toyota. It means that the sub-assemblies are ordered and come to line in a special Jundate vehicle. Figure 3.1.1: A part of Jundate The process chart for wheel sub-assembly includes thirty six steps. All of them specified according to basic motion elements. For example, take the screw or push the clamp buttons or bring the empty dolly for Jundate to the area. The total time spend while doing manual work is 771 seconds for 1 cycle.

And time spend while walking is 35 seconds for 1 cycle. So, total time spend for 1 cycle is 806 seconds. Toyota is an automobile producer. Automobiles are produced on an assembly line. This is an example of flow shop as expected. In plastic shop batch production exist. The examples of their products are information panel and bumper. In plastic shop, production, which is made from granules with injection method, is realized as batches. Then, they are painted. After paint, their subassemblies are made at plastic shop. Finally, they are sent to assembly line as sequential

With the help of sequential delivery, parts can be found at lineside at time. Assemble-to-Order (ATO) production system is mostly used system. It is related with pull system. All products produced at TMMT has already been sold. However, Toyota is not assembly factory. They produce some parts of the automobile. Therefore, in that department can be taken as an example of Make-to-Order (MTO) production system. For example, plastic shop makes its own production. Spare part productions can be another example.

I realized my IE400 intern at Toyota Motor Manufacturing Turkey plant at Adapazarı. It has 6 main facilities. 4 of them called as press & welding (body) factory, painting factory, plastic factory, assembly factory, final inspection and quality and production control. In press line, TMMT has 3 press machine. All of them presses different part with different specifications. The process in made with blanking line. Cold press is applied. In welding, different type of welding can be made; such as, arc welding, spot welding. In the near future laser welding will be started to