VLD treats CBUs like perishable goods since any delay or damage can negatively impact quality and customer loyalty. VLD is responsible for receiving CBUs from the plant and delivering them to dealers or ports while maintaining quality. For exports, VLD prepares documentation, conducts quality checks, and coordinates customs clearance and vessel loading to deliver CBUs on time. Continuous improvement is emphasized through kaizen to eliminate inefficiencies in operations.

1. LOGISTICS AND SUPPLY CHAIN OF CBU
(COMPLETE BUILT UNIT) IN TOYOTA
SAFETY FIRST QUALITY MUST
Faculty Guide Department Guide Presented By
DR. Ch. Venkataiah Mr. Arun Manager Gelli.V.S.Ch.Swamy
Chair person PGP Mr. Vijay N S, Asst. Manager
GSIB, GITAM University VLD, Toyota Kirloskar Motors

5. ARUN SAN
Manager of
VLD
VIJAY SAN
Asst. Manager
of VLD
SIDDESH SAN
Dy. Manager of
VLD
KEEPS THE FRESH QUALITY OF CBU FROM PLANT TO
CUSTOMERS
VLD treats, CBU is similar to perishable goods, if is there any delay in delivery
or damage in CBU it’s expensive and difficult to recover fresh quality of product
and we lose customer loyalty.

6. Production Receive Storage Dispatch
Port
Delivery
Shipment
Dealer
Delivery
Retails
Domestic :
Exports :
H/O from Plant H/O to LP
OVERALL VEHICLE LOGISTICS OWNERSHIP
RECEIVING CARS FROM PLANT – UPTO – DELIVERY TO DEALERS / PORT
....basically, we are the last link from TKM, in the Supply Chain

7. Getting the right product, to the right customer, in the right quantity, in the
right condition, at the right place, at the right time, and at the right cost
finally it increases the value of company
CUSTOMER
DEALERCUSTOMER TRANSPORTER
VLDPRODUCTION
SALES &
OPERATION
DEALER
In out-bound logistics communication between stakeholders plays a
vital role for improving the quality of services

8. CUSTOMER
GREET
SALES
EXECUTIVE
ABOUT
TOYOTA
TEST DRIVE
NEEDS OF
CUSTOMER
DEMONSTRATI
ONS
PRODUCT
PRESENTATIO
N
PAYMENT
SMILE &
E.M
ACCESSORIES
PLACE AN
ORDER
CONFORM B.P
DATE
DEALER CAN
RECEIVE C.B.U
ESTIMATED
DELIVERY DATE
ACCESSORIES &
STICKERING
WASHING
POLISHINGBUDJET,
FAMILY, DAILY
TRAVELLING
DISTANCES
DELIVERED
CASH/IN-
FIN/OUT-FIN
ENGINE,
SITTING,
FEATURES
4W D/L FINALIZE THE
COST
CONFORM THE
PAYMENT MODE
MAINTENANCE
Q.C
CUSTOMER
REQUEST
PAYMENT
DONE
1:5

9. WHEN CUSTOMER WAS READY TO PURCHASE CAR
MODEL ADVANCE BOOKING
PAYMENT
Etios, Etios-Liva 50,000
INNOVA 50,000
Corolla-Altis 50,000
Fortuner 1,00,000 lk
Camry 5,00,000 lk
L.C 200, Prado, Prius 10,00,000 lk
AFTER BOOKING CUSTOMER CAN CONFORM MODE OF PAYMENT
FULL CASH IN-HOUSE
FINANCE
OUT-HOUSE FINANCE
Balance Payment Date Finance Documents Bank Details
Registrations Finance Agreement With
Balance of Payment
Hypothecations Entry In
Bank(form 21)
Delivery Registrations Mode of Payment like DD
or E-transfer
Delivery Registrations
Delivery
SALES EXECUTIVES
TEAMS MODELS
3 Etios, Liva
3 Innova, Fortuner
1 Corolla, Camry
BUSINESS PROVIDED AT
TEAMS PLACE
2 Field
2 Showroom
2 Corporate
1 Government

12. DPP (M-15) H.O can Divided
Region wise Allocation
like E,W,N,S (M-14)
H.O can consolidate
and fix FIRM ORDER
(M-10)
By using FIRM ORDER
and DPP, H.O can
prepare ASSIGNMENT
up to LOD (M-7)
VLD can provide ETD
& ETA (M-5)
By using
ASSIGNMENT
VLD can prepare
R.O can divided Dealer
wise Allocations
H.O sales
L.P
R.O sales DEALER
M-2CTDMS
PRODUCTION VLDSALES

13. • Lot making
• Parked in Dispatch Bay
•Physically checked and
inform to EXERCISE
person
FUNDSPLAN
DEALER
CTDMS
MDDP
SAL
F.R can
Generated
FFB/I.F
STOCK
LOGISTICSFINANCE
CTDMSINVOICE
 Cross Check
Share that
Information to
EXERCISE person
15 mints

14. KEEPS THE FRESH QUALITY OF CBU FROM PLANT TO CUSTOMER
KAKU VLD
QC-
Gate
1
DISPATCH
QC-
Gate
2
NG
OK OK
NG
YARD
DEALER
TRANSIT
QC-
Gate
3
OK
POD
Inform
to
VLD/LP
BILL
NG

15. Customer Feel
Happy

16. DOMESTIC EXPORTS
COUNTRY NO. OF
SHIPMENTS
Liners
SOUTH
AFRICA
3/Month NYK/K-LINE
MOURITIUS 1/Month MOL
SEYCELLES 1/Month MOL
ZIMBABWE 1/Month NYK/K-LINE
SRI LANKA 1/Month NYK/K-LINE
ZONES OUTLETS 3S 1S 2S BP
EAST 28 21 7 0 0
3
WEST 50 33 13 3 1
2 3
NORTH 90 61 16 11 2
6 2 1
SOUTH 70 48 8 10 4
6 1
TOTAL 238 238

17. 100Km Lashing/
60kmph/ no ND/
460km per day
YARD-INVLDKAKU
OUT-TRAY
REMOVE
KANBAN
AND PLACE
DEALER
TAG/BAY
Num.
LOT
MAKING
SALES/
BILLING
INVOICE/6 EXCISE PERSON CAN CHK
THE DETAILS OF THE RESP.
FR Num. By RCV. MAIL
FROM FINANCE
VLD /
PHY CHK
DRIVERS CAN
PARK IN RESP.
BAY
QG-2
GRN/4
TRANSPORTER
E-SUGAM
SECURITY
PASSDRIVER
LP send TT as
per matrix/ LF
UN-LOAD
DEALER
QG-1
TRASIT
DOCUMENTS
BANKMDDP STOCK
E-TRANSFERMAIL
POD/
NVRR
QG-2

18. TKM
TMC/
TMAP
EXPORTER IMPORTER
CONTRACT
• PURCHASE ORDER
• SHIPPING SCHEDULE
CUSTOMS/
ENNORE
CUSTOMS/
DURBAN
TSAM
DELIVER POINT
TKM
CBU’S/ DOC. CBU’S/ DOC.
NEXT MONTH 25TH
LT- 12days
FOB ( Free on Board)
 D/C ( DOCUMENTS AGAINST CREDIT)

19. WHY SHOULD WE
EXPORTS?
GOVT. INCENTIVES (TOKENS)
INDO-THAI
ASIAN REGION (8 COUNTRIES )
FMS(FOCUS MARKET SCHEME)
FPS(FOCUS PRODUCT SCHEME)

20. • Wrap guard for export CBU on hood, luggage door, roof panel,
wrist handle.
• Anti rust papers for front wheel discs
• Owner manual book color i.e., Green for exports, Blue for domestic
• Mirror No Caution
• In Engine , Air cleaner with side branch
• VIN slot number at Windshield glass and chassis num on LH RR
door glass.
• Homologation mark was on wireless door lock control
• Engine control unit (ECU) software was changed
• Kaku, for exports we generate A4 sheet of Kaku
• Eye bolt was fitted in front of CBU, for lashing purpose in linear

21. LOT
MAKING
Yard inKaku
6 5
7 4
8 3
9 2
C 1
wind
ENNORE
PORT
OUT-TRAY
WITH BAY
no.
REMOVE
ONE
KAKU
AND
PASTE ON
A4 SHEET
LOT CONFORMATION
INVOICE/
3
VLD /
PHY CHK
DRIVERS
CAN PARK
IN RESP.
BAY
E-SUGAM
GRN/ 4
ARE/ 5
QG-1
QG-2
TRANSPORTER
SECURITY
PASSDRIVER
WITH- IN
36 Hrs
CONSULT
LP FOR
MATRIX/LF
SON
By using SON IMPEX
generate
DOCUMENTS
BAR CODE
SHEET

22. CASE
NUMBER
GENERATE
PRE-
ASSIGNM
ENT
CBU
SHIFTED
TO P-YARD
CBU
UNLOADED
BY DRIVER
VEHICLE
SHIFTING TO
GCB
CUSTOMS
CLEARING
(S-1)
CUSTOMS
INSPECTIONS
(S-2)
FINAL
ASSIGNME
NT (S-3)
PORT IN
CHK, write
vessel &
country name,
Barcode
OK
QC
NG
T.P.Y
IMPEX
INFORM
TO
LINEAR
Driver want to
submit
GRN, ARE,
INVOICE,
BARCODE Sheet

23. DOCUMENTS GIVEN By EXPORTER
To CUSTOMS
•EXPORT INVOICE
•SHIPPING BILL
•EXPORT VALUE DECLARATIONS
•SELF DECLARATIONS
•SEA WAY BILL

24. CUSTOMER
DEALERCUSTOMER TRANSPORTER
VLDPRODUCTION
SALES &
OPERATION
DEALER

26. 0.00%
20.00%
40.00%
60.00%
80.00%
0.00%
2.00%
4.00%
6.00%
8.00%
10.00%
12.00%
14.00%
India Europe U.S Japan
27%
23%21%
7%
4%
5%
4%
4%
3% 2%
Automotive
Engineering
Others
Chemicals/Fertilizers
Metals
FMCG
Textiles/Apparel
Services
Telecommunications
Transportation
SHARE
COST

27. TKM
TCI
TLKI
TLI
KTS
TOYOTO
YUSO
TTC
MITSUI
SUB CON
LISTED-769 TT
51 DEDICATED
SUB CON
LISTED-1149 TT
115 DEDICATED
LP’S
J.V
TKM MDDP
Sub con’s are
interested on
particular zones
only
TLKI-CC person can
generate DDP for whole
month by sync. Zone-wise,
dealer-wise
64%
36%
22%
51%
51%
49%
27%

28. TKM
TLKI
SUB CON
send CC
S-14
TLKI 51 SUB-
CON’S
C-17B-19A-11
TRAINING
/ TESTING
EDUCATION
OTHER
OEM’S
REPAIR
INSP
ECTI
ON
NG
OK
10K
10K
For loading
it takes
2days,
driver
wages
3k=23k
•NO INSPECTION,
•NO REPAIR COST
•NO TRAINING,
•NO TESTING,
•NO WAITING COST
20K
ON DAY
LOADING
….ASSUMPTION

29. EDUATIO
NS/
TRAINING
CC
INSPECTI
ON
CCM/
FLEET
Mang.
TT
FROM THE PLAN
OF TKM, TLKI
MEMBER CAN
SHARE THE
INFORMATION
PARK
SEND CC
TO TKM
DISPATCH
CONTROL
LER
TOTAL 77
CHK
POINTS
PRE-
DISPATCH
ROOL CALL
VMD
INFORM
BAY
NUM
DISPATCH DOCUMEN
TATION
LOADING
WAITING
FOR
INSPECTION
DEALER
DAILY ROLL
CALL
2TIMES ROLL
CALL,
60KMPH(over
speed), night drive,
lashing chk for
100km… UPDATE in
TKM WEB-TRACK
POD/ NVVR
UNLOADING
QC

30. CUSTOMER
DEALER
SALES
PRODUCTIONVLD
LOGISTICS
PARTNER
DEALER

31. 1. At kaku area, kaku person can miss handle the form-22. because he want
to close the hood and open the door by carrying form-22 & kaku labels.
Counter measure: Prepare Proper Sop For Carrying Form-22
2. Delay in billing, Waiting until 11a.m due to this the dispatch was started
after 11.30 only and its make burden on closing time of day.
counter measure: We Hope For Coming Months Sales Become Stable
3. washing bay, with washing dispatch the cycle time is 12mints and without
washing dispatch the cycle time is 8mints.
Counter measure: Automatic Washing System Or Water Spray In Yard
4. If heavy winds are coming due to clouded sky, we want to check the yard
due to quality & damage issues, it was happen after we identify heavy wind
flow. So there is a chance any object is hit to CBU.
Counter measure: Place A Wind Identifier, By Placing This Instrument It
Gives Alarm Before Wind Was Coming(expensive).
Toyota gives more importance to Kaizen for every
operation
Its main objective is to Eliminate 3M’s(MUDA,
MURA, MURI)