“Consideration of production quantities and statistics”
Picture #1 Toyota Prius assembly line end
Video: “Megafactories: Toyota Australia” Here in this documentary, the “Toyota way” is explained thoroughly, starting from a good quality panels pressing. Also reports the challenge of the new Australian factory, to produce “in house” the AR engine to high qualitative standards in order to compete with the other Toyota’s plants. Where mechanical robots cannot reach or check the quality of the component there’s still human labor used to make sure the part is up to qualitative standards. The production team is also very important and can contribute to improve and innovate the assembly process by proposing new solutions. These solutions if successful can be adopted to constantly improve and facilitate the job. Every task is studied to last not more than 120 seconds. As for the final quality inspections, 95 items to check within the same time margin. This demonstrates a clear focus on their customer’s needs and expectations, which in the last years has increased. Nowadays more than ever safer, more ecological, reliable, more fuel efficient and qualitative cars are requested to stay competitive within the market segment.
Toyota is a global manufacturer. Their production is advertised as “lean”, although the units assembled each year clearly define it as a mass production brand. With 150.000 vehicles produced each year just from the Australian plant, Toyota production carefully considers efficiency within the assembly line. Apparent efficiency is yet to be avoided by considering the amount of units needed first. To therefore get the true efficiency the rest of the process and labour hours has to be slowed down or reduced accordingly. The “Just in time” strategy is adopted to eliminate inventories and therefore the risk of potential defects of stoked parts or faulty machines. Another system is the “Pull” which replaces only the items needed by the customer at that specific moment. This system is also used to avoid parts kept in stocks because components are ordered from suppliers just after the customer had placed his order. Also to avoid defected components, another solution is to adopt the “Continuous flow process”, which prevents parts congestions between manufacturing processes. With an average of eight million vehicles produced worldwide each year, Toyota is certainly one of the most advanced in efficiency of production.
Edoardo Pandolfini Barberi 24/11/2013
Inc. (2013) “Toyota production system basic handbook” Art of Lean [Online] available from:
Daniel Jones (2013) “Leaning toward” Lean UK [Online] available from:
Kentucky Cabinet (2013) “Kentucky is a driving force in the U.S. automotive industry” Think Kentucky [Online] available from:
National Geographic (2013) “Megafactories:Toyota Australia” Youtube [Online] available from:
[1st July 2013]
Picture #1 [Online] Japan Local Government Centre London UK, available from: