Enhancing a Tripled "People-friendly," Cost-conscious, and Earth-conscious Kaizen Methodology at an Automotive Manufacturing Facility

In the heart of Toyota City, Aichi Prefecture, Toyota's engine plant at the Kamigo Plant continues to be a cornerstone of the company's operations, producing an impressive 1.33 million units annually. Established over half a century ago, this plant has been dedicated to engine production and now boasts a diverse lineup, from 1.5L units to 3.5L units.

A significant change in the plant's operations has led to a substantial reduction in annual CO2 emissions. The introduction of the Super Skill (SS) Line, built in 2013 to create a workspace for rehired elderly workers, has been instrumental in this reduction. The SS Line uses karakuri mechanisms, a traditional Japanese technology, to move objects by using their weight, eliminating the need for electricity.

One of the key improvements on the SS Line is the new binding agent and regeneration furnace technology. This innovation has eliminated the need for deodorizer ducts, reducing the amount of CO2 required to produce a single cylinder head by approximately 1.8kg. As a result, the SS Line is responsible for an annual reduction of approximately 1,800 tons of CO2 at the plant.

Moreover, the new regeneration furnaces used to recycle sand reduce the amount of energy used and are compact enough to be installed on each production line. This not only contributes to the reduction of CO2 emissions but also promotes energy efficiency.

The SS Line's design also allows for immediate identification of any processes causing difficulty. This feature, coupled with the elimination of missing washers on head bolts, a mechanism implemented to prevent engine malfunctions, ensures the highest quality standards are met.

Since 2017, the plant has also started producing engines developed based on the Toyota New Global Architecture (TNGA). This new process is being used in other plants around the world, with the potential to reduce CO2 emissions by 4,800 tons when 2.7 million cylinder heads are produced with this approach.

As of June 2021, there are 3,441 employees at the plant, working together to maintain Toyota's commitment to sustainability and quality. Hirofumi Matsuoka, responsible for overseeing the resumption of vehicle engine production at Toyota, ensures that the process is efficient and meets quality standards.

Despite being a significant CO2 emitter among Toyota's domestic plants, as noted in 2020, the Kamigo Plant continues to innovate and implement measures to reduce its carbon footprint. The plant's cleaner, more efficient production processes not only benefit the environment but also contribute to Toyota's mission of achieving a carbon-neutral society.

Enhancing a Tripled "People-friendly," Cost-conscious, and Earth-conscious Kaizen Methodology at an Automotive Manufacturing Facility