ATS Inspect Toyota Case Study

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The Toyota Quality Division involves
various inspection cells, that check
certain parts of the manufactured
vehicle.

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ATS Inspect Toyota Case Study

  1. 1. Toyota Motor Company Australia Case study ATS Inspect 02/11/2009 Page 1 Case Study - ATS Inspect - Toyota Australia www.ats-global.com
  2. 2. TMCA Requirements & Goals Record every single defect Report defects discovered back to responsible area – real time Inform Quality Managers when serious issues arise (email / SMS) Reduce number of defects Improve Straight Through Ratio (Vehicles without defects) Remove paper where possible Provide KPI reporting to the plant floor 02/11/2009 Page 2 Case Study - ATS Inspect - Toyota Australia www.ats-global.com
  3. 3. Toyota - Inspect Solution 02/11/2009 Page 3 Case Study - ATS Inspect - Toyota Australia www.ats-global.com
  4. 4. Defect Inspection Stations The Toyota Quality Division involves various inspection cells, that check certain parts of the manufactured vehicle. Drum test Wheel Alignment Shower Customer Satisfaction Upon vehicle entering the inspection cell: Operator scans the barcode VIN (Vehicle Identifier Number) On ATS Inspect that unique vehicle appears Quality operator inspect part(s) The defects found are recorded in ATS Inspect by touch screen clicks 02/11/2009 Page 4 Case Study - ATS Inspect - Toyota Australia www.ats-global.com
  5. 5. Defect Repair Stations (Hanedashi) Any vehicle with defects that can not be repaired in the Inspection Station is moved to the Hanedashi area (repair area). Upon vehicle entering the repair cell: Operator scans the barcode VIN (Vehicle Identifier Number) ATS Inspects displays a list of all vehicles recorded for that unique vehicle. Operator repairs defect(s) Operator marks defects as repaired in ATS Inspect. 02/11/2009 Page 5 Case Study - ATS Inspect - Toyota Australia www.ats-global.com
  6. 6. Plant floor Andon Board Plant floor Andon boards are used to feed back any quality issues real time to quality operators. ATS Inspect database structure allows for reporting in any form required. Reported KPI’s include: Straight Through Ratio (STR) per inspection cell Average number of defects caused by manufacturing area Top 5 defects recorded, providing the defect, part, location, quantity and responsible area 02/11/2009 Page 6 Case Study - ATS Inspect - Toyota Australia www.ats-global.com
  7. 7. Assembly Control Room – Wall Projector Provide Real Time feedback on large projector screens in the assembly control room, by utilising custom made Advanced Inspect Reports. This allows for immediate reaction on any rising issues or ‘trends’. Defects caused by Assembly lines and it’s Target for current shift. [Top graphs] Defected vehicles by inspection cell for current shift [Bottom left] Straight Through Ratio by assembly line and by plant [Bottom right] 02/11/2009 Page 7 Case Study - ATS Inspect - Toyota Australia www.ats-global.com
  8. 8. Impact of Inspect Operator ATS Inspect ATS Inspect Steady decline Training Implementation in use in defects Period The total number of defects discovered on all vehicles inspected in the 02/11/2009 QDC area (by month). Steady decline of number of defects. Page 8 Case Study - ATS Inspect - Toyota Australia www.ats-global.com
  9. 9. ATS Inspect Achievements Toyota after using ATS Inspect for 1 ½ years: Reduced the number of average defects per month from ± 20.000 to ± 5.000, and continue to improve. Removed all paper in the Quality Control Division Reduces number of resources involved with quality data gathering and reporting (retrained and moved in organisation) Real time feedback on issues 02/11/2009 Page 9 Case Study - ATS Inspect - Toyota Australia www.ats-global.com
  10. 10. 2009 Manufacturer of the Year Award Despite tough economic times, this year’s Endeavour Awards demonstrated Australian manufacturers are up to the challenge. Katherine Crichton reports from the gala Award’s ceremony in Melbourne. “The world is going through some very tough times right now – and when times are tough, it is the manufacturing sector we look to for new ideas and new hope." This was the message Industry Minister Senator Kim Carr delivered at the sixth annual Endeavour Awards gala dinner ceremony held in Melbourne last night which saw Toyota Australia take out the prestigious 2009 Manufacturer of the Year Award. 02/11/2009 Page 10 Case Study - ATS Inspect - Toyota Australia www.ats-global.com

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