Toyota Kirloskar Motors Jit

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Toyota Production System

at TOYOTA KIRLOSKAR MOTOR PRIVATE LIMITED

CONTENTS:
1 2 3 Introduction to Toyota Profile of Toyota Kirloskar motor. Toyota Production System practices in TKM.

4 Overview of TKM Logistics.
• • Just In Time Kaizen- (Continuous Improvement in logistics)

5

Future “Supply Chain” Direction.

TOYOTA MOTOR CORPORATION
• Established in 1937 in Japan • 160 Countries - 5400 Dealers. • 26 Countries - 46 Plants • Sales of 15.1 trillion Yen in March 2002 • 247,000 employees worldwide. • Manufacture of all types of Vehicles including Luxury & Small Cars.

Automakers ranking worldwide based on vehicle sales
9000 8000
No. of Units Sold (1=1000 Units)
2003 First quarter Result Toyota – No. 2

7000 6000 5000 4000 3000 2000 1000 0
GM Ford Toyota VW Daimler Chrysler PSA Honda Nissan Renault Fiat

Company

Toyota is 3rd Largest Auto Maker in the World

TKM is the 14th & almost the last automobile manufacturer to enter in Indian automobile industry

TOYOTA KIRLOSKAR MOTOR PRIVATE LTD
Establishment Location Start of Production Production Model Production Capacity Investment No. of Employees : : : : : : : 6th October 1997 Bidadi near Bangalore in Karnataka State Dec 1999 Multi Purpose Vehicle Passenger car 50,000 Units/year US$ 170 Million (Phase I) 2300

PRODUCTION / SALES
50000 40000 Volume 30000 20000 10000 0
Corolla Qualis 21086 28509 2000 2001 2002 1383 28989

Crossed 1Lakh cars in Sept 03

2003 9000 34000

COMPLETE VIEW OF TKM PLANT

In-house facilities at TKM
Press Shop Weld Shop Paint Shop

Assembly Shop

Inspection Area

ISO 14001 WITHIN THE FIRST YEAR

TPS AT TOYOTA KIRLOSKAR MOTORS

IMPLEMENTATION OF TPS IN TKM
TAKT UP (7.5’ - 7’) & TAKT UP (9.25’ TAKT DOWN START OF TAKT - 8’) (7’ TAKT UP - 8’) UP (10’ TAKT UP - 8’) i TAKT UP - 7.5’) (12’ - 9.25’) (8’ 3000START OF SECOND t (9.25’ - 8’) TAKT DOWN s SHIFT TAKT DOWN (8’ - 10’) 2500 / (8’ - 9.25) TAKT DOWN TAKT DOWN M (9.25’(8’ 12’) 9.25’) - o

3500 n

U

VEHICLE QUALITY TREND

2000
n t 1500 h

Just In Time
70.00% 68.00%

Standardized Work
GLOBAL TOYOTA LEVEL REFORM

LEVEL

IMPROVEMENT

TKM

0

AS ON DATE

MAINTENANCE

TIME

M-I-R

START OF VOLUME PRODUCTION

1000 500 0
Dec- Jan99 00 Feb00 Mar- A p r - May- Jun00 00 00 00 Jul- Aug- Sep00 00 00 Oct- Nov- Dec- Jan00 00 00 01 Feb01 Mar- A p r - May- Jun01 01 01 01 Jul- Aug- Sep01 01 01 Oct- Nov- Dec01 01 01

Heijunka
This is the average yield ratio of all the suppliers I.e. STTI,

Visual Control Board Built in Quality

GLOBAL YIELD RATIO COMPARISON

This data excludes 15.474 kg/veh of material saved by sending offals to supplierpartslikeNTTF,STANZEN&

QUALIS BASIC YEILD RATIO 66.00%

64.00%

62.00%

TPS
133W133W 797T 2 1 4 0 N 0 4 351T 143N 4 3 9 3 T 0 T 0 5 231T 0W 325N 316T 0W 3 T 0 T 7 6 4 9 415T4 0 0 T 0 395T 0W 2 186N 465N 4 153T 391T 9 0 4 T 6 1 5 0 T 5 0 T 7 8 652T 651T 6 7 0 1 T N 3 0 525T 828T 191N0 0 2 T T 9 133W971T 6 1 5 N 0 0 0 9 8 5 7 541T 8 T T 1 0 N 1 T 6 5 2 0 4 5 0 T 0 0 8 9 T T 5 0 8 477T 8 N 8 9 T 0 T 7 185T 7 277N 781T 0 T 8 0 T 60 3.42%06 00 00 00 00 00 00 00 00 00 00 00 00 00 20 00 00 00 00 00 00 00 00 00 1.26%00 00 00 00 00 00 00 00 00 00 00 00 00 05 00 00 00 00 00 00 00 00 00 1.48% 00 00 00 00 0% . 5% 0% 0% 5% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% . . . . . . . . . . . . . . . . . . . . . . . . 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 8% 0% 0% 0% 0% 0% 0% 0% 0% 0% . . . . . . . . . . . . . . . . . . . . . . . 0% 0% 0% 0% . . . . 61% 61%90 67% 69% 64%80 64% 62%80 68.00%69%70 66% 62% 62% 68%60 65%67 61% 00%68% 65%50 63% 67%40 68% 68% 68%40 66% 62% 62%46 61% 61% 67%39 65% 61% 00%68% 68%20 66% 65% 65%20 60.70%62.00%65% 86%57% 40 40 62% 90 80 80 68% 80 80 61% . . . . . . . . . . 79 69% 75 77 70 40 65% 60 62% 60 66. 50 50 64% 50 30 69% 40 40 40 67% 40 40 40 61% 40 40 30 65% 20 30 63. 20 20 66% 20 27 20 65% . . . . . . . . . . . . . . . . . . . . . . . . . ....
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