Evolving Instrument Panel Parachute: A Continuously Innovating Safety Feature
In the heart of Toyota's Motomachi Plant, a shining example of continuous improvement, or Kaizen, can be found in the form of an ingenious mechanical system. The instrument panel chute system, a testament to the plant's commitment to making work more enjoyable and efficient, is a prime example of the plant's creative use of traditional Japanese concepts, known as Karakuri.
Karakuri, meaning 'clever mechanical tricks', has been employed by Toyota to tackle the challenges of high-mix, low-volume production. This approach involves the use of clever mechanical solutions to manage the diverse range of products and low production volumes efficiently.
The instrument panel chutes, a key part of this new system, are controlled by Karakuri and require no power. They are designed to transport parts or components efficiently, reducing manual handling and minimizing errors. This innovation has led to the elimination of the need for Automated Guided Vehicles (AGVs), solving the plant's traffic jam problem.
Eiji Nagayama, Senior Expert of 2NB Team, Assembly Section No.1, discusses the challenges in managing various car models and their components. He oversees the team responsible for building improvements and maintaining safety within the plant. Nagayama believes that creative ideas are essential for establishing conditions where tasks are easy for anyone to understand and perform.
The Motomachi Plant's use of Karakuri extends beyond the instrument panel chutes. The team has overhauled the traditional parts storage system, replacing it with a system using parts trays controlled by Karakuri. Even the stopper release in the chute system is linked to the vertical movement of the wheeled rack and the action of the weight.
Nagayama views Kaizen as something that rewards persistence and continuous development of improvements. He is pleased that these innovations have made work easier for the genba technicians and sees them as a meaningful approach toward decarbonization.
In an era of increasing diversity, creating an environment where tasks are easy to understand and perform is crucial. The Motomachi Plant's implementation of Karakuri-based Kaizen is a significant step towards achieving this goal. The plant continues to face issues with overcrowded temporary storage areas and congestion caused by AGVs and parts transporters, but with the successful integration of Karakuri, it is well on its way to streamlining its workflow and enhancing its manufacturing processes.
In the application of Karakuri within Toyota's Motomachi Plant, data and cloud computing technology are utilized to optimize the ingenious mechanical system for efficient high-mix, low-volume production. This integration is evident in the design of the instrument panel chutes, which are controlled by Karakuri, requiring no power, and the overhauled parts storage system using Karakuri-controlled parts trays.
