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Toyota Motor Manufacturing France has set itself the goal of building vehicles with
the highest levels of built-in quality in the B segment.
The Yaris has already established a reputation for the highest levels of quality, durability
and reliability. Such quality can only be assured through its comprehensive integration
of every facet of the Toyota manufacturing process.
We set three internal priorities for the new Yaris launch. First, we identified the improvement
point from each of the current Yaris production areas.
Very early in the project we incorporated all these requirements into the development
of the new vehicle structure.
Secondly, through proper training as well as a review of the skill we wanted to ensure
a smooth transfer of the new Yaris assembly operation to the plant members.
Finally using our continuous improvement philosophy we looked at how to further improve building
quality in our manufactuing process, based on Toyota production principles.
TMMF engineers were involved in the development of the new Yaris for three years before the
start of production, a year and a half longer than on the previous generation vehicle.
All manufactuing and quality departments sent several engineers to Japan for between six
and 18 months to study and further improve the vehicle design.
This is to ensure that every part has been designed for more consistent quality over
the course of repeated manufacture allowing for greater control of both fitting accuracy
and build quality.
Last year I spent 8 months in the quality control division of the Toyota plant in Japan
with responsibility for accuracy improvement and preparation.
This assembly evolution stage is key in the body development in order to properly prepare
for the future production at the French plant.
I work closely with suppliers on the design of tools and jigs such as Toyota bracket to
improve every aspect of working ergonomics for assembly members.
Poorly designed parts and awkward fitting processes not only have a negative impact
on vehicle build quality but also on assembly line members working posture and potentially
their health.
TMMF feadback on the assembly process has also allowed TMC engineers to optimise both
the finger pressure required to fit parts to the vehcle and the control sounds such
as a click which confirm proper fitment.
During the trial assembly period preproduction units were measured in 3 D to check the geometry
and dimensions of the body shell against the established datum.
This process highlighted any inconsistency of body part shape or size as well as any
misalignment or gap management issues.
The direct involvement of suppliers in the production preparation process was also essential
to ensure the highest possible quality.
Every supplier visited TMMF on a regular basis both before and during assembly trial periods
for the new Yaris.
A dedicated area was set up with in the body shell zone for extensive discussion design
reviews and trial parts fitting with the aim of identifying all potential problems.
The expert training of assembly line members is fundemental to both maitaining and further
improving the highest levels of built in quality.
Basic non vehicle specific skills such as nut and bolt tightening and connective fit,
clip fit and hole-plug fit or screw fit techniques are developed in fine detail. Moreover even
experienced members undergo regular update training to reinforce these basic assembly
line skills.
Six months before the start of production all members are trained on all manufacturing
processes. First offline to learn and repeat correct assembly techniques and then online
to confirm quality of workmanship.
Based on the Toyota Kaizen philosophy every quality check procedure was improved.
We improved the quality control inspection process to further raise the quality of the
final vehicle. We are continuously striving to reduce any small internal defect even though
that will not be perceived by the customer.
Cross functional business reform working groups focussing on design, quality suppliers and
production were also established.
Their aim is to review critical process characteristics to guarantee the built-in quality of five
critical functions - braking, acceleration, turning, fuel leaks and potential fire-starting
points. This also further improves quality conciousness from team members as well as
strengthening warranty management and the critical audit process.
We listened carefully to the feedback from current Yaris owner. We are confident that
we will deliver vehicles with both improved perceived and built-in quality. This will
surely allow us to maintain the Yaris reputation for the highest levels of quality reliability
and durability in the B segment.