Globally, Toyota has indicated a strong and diverse commitment to the pursuit of harmonious growth through its technically advanced and environment-friendly products. There have been relentless efforts in the crucial fields of mobility, city transportation, resources, society and environment, through research & development.

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AN EXPLORING VIEW ON THE PRODUCTION SYSTEM OF
TOYOTA KIRLOSKAR MOTOR PRIVATE LIMITED INDIA
VARUN KESAVAN, RESEARCH SCHOLAR, E – MAIL ID – varunkesavan@yahoo.com
INTRODUCTION
Globally, Toyota has indicated a strong and diverse commitment to the pursuit
of harmonious growth through its technically advanced and environment-
friendly products. There have been relentless efforts in the crucial fields of
mobility, city transportation, resources, society and environment, through
research & development.
Protecting the environment has always been a priority at TKM, starting with
the eco-friendly engines that are manufactured for the Toyota vehicles, to the
advanced technology that is used for purification or recycling of waste water at
the plant. Apart from this, the plant at Bidadi, Karnataka, is surrounded by a
green belt, meets high environmental standards and has achieved the ISO
14001 certification in its very first year of operations.

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Quality is ensured in every vehicle that rolls out of Toyota Kirloskar Motor,
through in-built audits at every process of the system. The company's
operational excellence is based on the improvement tools and methods
developed by Toyota under the Toyota Production System (TPS), greatly
emphasizing superlative quality and minimal waste.
In line with Toyota's growing comfort with its India operations, the company
set up Toyota Kirloskar Auto Parts (TKAP), which commenced production of
transmissions in May 2004, for its global requirements. Another initiative is the
Toyota Techno Park India (TTPI), a non-profit industrial infrastructure
company aimed at boosting local industries and related job opportunities.
Setting benchmarks for the automobile industry, the manufacturing facility
consists of 4 divisions (shops) - Press, Weld, Paint and Assembly.
Press Shop Weld Shop

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Paint Shop Assembly Shop
TOYOTA PRODUCTION SYSTEM
Toyota Production System (TPS) combines a balanced mix of human
resources and robot technology for increased productivity. This system
involves two important principles:

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Jidoka - building quality into the production system and ensuring damaged
parts do not proceed to the next stage.
Just In Time (JIT) - making only what is needed, when it's needed, and only
as much as is needed.
Eco Factory: As part of our sustainable plant initiatives, the plant is designed
with an Eco-Factory concept to maximize the output with minimum input by
creating a highly optimized manufacturing process.
From our energy efficient servo press to our state-of-the-art global body line,
we are able to reduce process steps to further increase our energy efficiency.
We also use water borne paint and a water recycling system that recycles
40% waste water back into the process, thereby leading to higher resource
optimization and contributing towards a greener society