"One Day Craftsman" explores the ingenuity of GAC Toyota

GAC Toyota products have always been synonymous with "high quality" in the minds of consumers, which is the embodiment of GAC Toyota's ingenuity in casting products with ingenuity. Since 2016, GAC Toyota has held the "One Day Craftsman" Quality Open Day every year, aiming to let more people understand how Toyota's quality is trained and share the latest achievements of ingenuity.

This year is the sixth quarter of GAC Toyota Quality Open Day, taking this opportunity for GAC Toyota to let consumers understand the advantages of dual-engine hybrid technology under TNGA through quality lectures and workshop visits, explore the core of GAC Toyota's quality management - "self-process completion" concept, and work with the "black hat" craftsmen of the independent product insurance supervision class to "find fault" for product cars and feel the quality essence behind GAC Toyota's "zero defect rate" factory.

This year's "One Day Craftsman" exploration site is GAC Toyota's second production line, where the production of Camry, Willanda, Highlander and other models, each car needs to go through stamping, welding, painting, assembly, inspection of five manufacturing links, each link is in accordance with Toyota's highest global standards requirements for production.

Of course, GAC Toyota controls product quality from the source. 2 sets of offline material cleaning machine, 7 servo stamping production lines, more than 90% of the large stamping parts, the proportion of leading the industry, to maximize the quality of stamping. GAC Toyota uses high-precision welding robots to dot, ensuring the accuracy and strength of the solder joints, and the welding has reached the industry-leading level. Not only that, GAC Toyota relies on the "two pillars" of just in time (JUST IN TIME) and self-service to control the quality of the final assembly steadily. "Punctuality" avoids waste and improves efficiency; self-service with the word "human" requires people and machines to automatically judge the quality of the process, stop and improve in time when problems are found, do not let quality problems flow into the next process, eliminate parts assembly errors, meet Toyota's highest global standards, and build Toyota's "zero defect rate" factory.

On the production line of GAC Toyota, yellow and red drawstrings are set up above the workstation, as well as eye-catching monitoring displays, which is the Anton system that visualizes quality problems. Whenever the production line employees encounter an abnormal situation that cannot be solved, immediately pull the Anton pull rope, the display screen will timely feedback the problem point and the station, the line work team leader immediately deal with it, if the vehicle is still not solved before reaching the next station, the production line will automatically stop.

Any production line employee has the right to stop the production line and let the quality problem be solved "at the time and locally", which also ensures the first-class quality control level of GAC Toyota to the greatest extent. In order to avoid the tightening caused by accidental errors and omissions, GAC Toyota has introduced a "error-proofing system", which automatically stops the equipment when the error occurs, and the tri-color lamppost of the Anton system will automatically alarm the indication. For example, when the bolting operation begins, the blue light is lit. Only when the operator tightens all the bolts can the green light be lit and the station can be passed. Otherwise, the Anton system will automatically alarm, the red light will be lit, the production line will stop, until the team leader will solve the problem, 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.

In addition, in the GAC Toyota plant, there is a secret quality base independent of the manufacturing department, and they firmly control the production level of GAC Toyota with ultra-strict standards - the independent inspection class of the quality assurance department. Even vehicles that are qualified by the production line must strive for excellence, constantly discover new problems, and find the source to improve. Wearing a black hat with the SQA (Self-Insurance Supervision) logo, the inspectors evaluated the quality of the vehicle from the customer's point of view according to toyota's same methods and benchmarks around the world, and evaluated more than 1500 items, which was called "picking bones in eggs". In order to achieve the ultimate in quality, the independent inspection class has even set higher standards on the basis of Toyota standards.

Last year, the one-time pass rate of GAC Toyota's production line increased to 99%, leading the industry average by 10%, the vehicle defect dropped to 0.01 pieces/unit; the supplier parts defect rate decreased to 0.29PPM (that is, only 0.29 defects out of 1 million parts), and good quality laid a solid foundation for sales growth. In the first ten months of this year, GAC Toyota sold more than 660,000 vehicles. Behind the eye-catching sales is that GAC Toyota's craftsman quality has always been indispensable. To achieve better quality, continuous breakthroughs and continuous improvement, this is also the craftsman spirit that GAC Toyota is committed to conveying to consumers.