At this year's Guangzhou International Auto Show, GAC Toyota released a new corporate strategy, saying that it will sprint to the sales target of one million vehicles in 2022, and launch three strategic actions such as "comprehensive product high-end", "all-round electrification" and "all-field science and technology" to build a million-vehicle system in an all-round way.
Since the full update to the TNGA architecture, GAC Toyota's products, such as Highlander, Veranda, Camry, Leiling, Xena, etc., have shown more fierce momentum in various market segments. According to the latest data, GAC Toyota's total sales in November reached 85,000 units, an increase of 9.8% year-on-year, and its cumulative sales from January to November reached 729,000 units.
Behind this, it is inseparable from the gac toyota plant's pursuit of quality "zero defect rate", which is the solid foundation and major mystery of its steady increase in sales and the creation of a million system.
The ingenuity of all employees is to strive for excellence
The craftsmanship spirit of excellence and continuous improvement has created a high reputation for toyota's quality.
Adhering to the concept of "building cars and educating people", GAC Toyota Factory will formulate corresponding incubation plans according to the level of each employee, and adjust the plans through regular training and assessment, so that everyone can grow efficiently. Before new employees participate in the actual production, they need to go to the workshop quality corner to learn and experience, and establish a sense of quality priority.
At the same time, GAC Toyota also carried out the "Best to The Best - All-Staff Ingenuity Action" throughout the company, from managers, engineers to front-line craftsmen more than 8,000 employees actively participated in continuous improvement, and submitted 12,000 quality improvement cases every year, with an adoption rate of 99%.
With the efforts of all the craftsmen, the manufacturing quality of GAC Toyota has continued to improve. In 2020, the one-time pass rate of GAC Toyota's production line increased to 99%, 10 percentage points ahead of the industry average; the defective vehicle fell to 0.01 pieces/unit; and the supplier parts defective rate decreased to 0.29PPM (that is, only 0.29 defects out of 1 million parts), setting a model for the automobile manufacturing industry.
Advanced workshop multiple "defense lines"
GAC Toyota controls quality from the source, and every link is produced in accordance with Toyota's highest global standards. The second production line of Nansha factory alone has 2 offline material cleaning machines, 7 servo stamping production lines, and more than 90% of large stamping parts are made in-house, leading the industry in proportion, maximizing the quality of stamping. The welding workshop adopts all high-precision welding robots to dot, and the welding has reached the industry-leading level.
As Toyota's "zero defect rate" plant, GAC Toyota relies on the "two pillars" of just in time and self-service to control the quality of final assembly. "Punctuality" avoids waste and improves efficiency; automation with the word "people" requires people and machines to automatically judge the quality of the process, and when problems are found, they can stop and improve in time, so as not to let quality problems flow into the next process.
It is worth mentioning that on the production line of GAC Toyota, yellow and red drawstrings are also set up above each station, as well as eye-catching monitoring display, which is the Anton system that visualizes quality problems. Whenever the production line employees encounter an abnormal situation that cannot be solved, they immediately pull the Anton pull rope, and the line work team leader immediately deals with it, so that the quality problem can be solved "at that time and locally".
In order to avoid the poor tightening caused by accidental errors and omissions, GAC Toyota has also introduced a "error-proofing system", in which the equipment automatically stops when the error is made, until the problem is solved, and the production line can start again, effectively preventing the phenomenon of leakage and tightening. This is an important part of the quality assurance of the final assembly process, and it is also one of the details of the ingenuity.
The ultimate standard for "black hats"
Like other Toyota plants, GAC Toyota also has an independent inspection class of the Quality Assurance Department, which is a secret quality base independent of the manufacturing department, and the inspectors wearing black hats firmly control the finished product standards with ultra-strict standards.
At this time, the "black hat", from the customer's point of view, uses more than 1500 detailed assessments to evaluate the quality of the vehicle, even if this is a production line to determine the qualified vehicle. In order to achieve the ultimate quality, the standards set by GAC Toyota's "black hats" are much higher than the requirements of Toyota Motor. For example, most car leather seats will make a friction sound when they sit down, and Japanese factories do not think that this is a defect, but GAC Toyota's inspectors consider this situation from the perspective of Chinese consumers, determine this situation as a defect, and require suppliers to choose softer seat materials to improve the consumer experience.
(Xinmin Network publishes this article for the purpose of transmitting automobile information, which does not represent the views of this website)