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"There must be a road before the car reaches the mountain, and there must be a Toyota car on the road", this advertising slogan that has been popular since the 1980s must have been heard by many small partners, but how is a Toyota car produced? How is toyota made of high quality? The above problems are probably not clear to most people.
TNGA is an acronym for Toyota New Global Architecture. As a value innovation system of the whole industry chain including research and development, design, production, procurement, etc., TNGA is a new car-making concept and methodology pioneered by Toyota, and has 4 innate "genes" - cool, driving fun, safety and intelligence.
TNGA is not only embodied in the generalization of the core advantages of each model, but more importantly, with the help of this system, Toyota factories around the world can share information and synchronize corrections, so as to achieve "consistent quality" for all out-of-the-world vehicles.
In order to ensure the high quality of the whole process, TNGA will let the design and development, production technology, manufacturing management personnel in the three major links of design and development, production technology and manufacturing management at the beginning of the design of each new car, fully absorb and adopt the opinions of all parties. In the mass production stage, TNGA also attaches great importance to the synergy of subjective and objective factors, on the one hand, it continues to optimize the conditions of good products, on the other hand, it emphasizes the implementation of "self-completion", and consolidates the quality cornerstone with the ingenuity of all employees.
It is reported that since the promotion and application of TNGA, there are 12,000 quality proposals from all links and levels every year, and the adoption rate has reached 99%. At GAC Toyota, the excellent quality control effect brought by TNGA is even more surprising - the one-time pass rate of the production line is 99%, which is about 10 percentage points ahead of the industry average. The defective rate of vehicle inspection and supplier parts are controlled at 0.01 (only 1 defect per 100 units of vehicle appearance defects and dirty inspection) and 0.29PPM (only 0.29 defects in 1 million parts).
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Introduction/stamping workshop of GAC Toyota Nansha Plant
According to GAC Toyota, the one-time pass rate of GAC Toyota's production line reached 98.8% in 2017. The unqualified rate of parts and components is 0.38PPM, that is, only 0.38 of the 1 million parts are unqualified products.
Press Shop:
The work of the stamping workshop is the step of stamping the raw steel plate material through the press into the shape required by the vehicle.
The stamping workshop of GAC Toyota Nansha Plant produces a total of 53 sets of molds and 71 parts in the new eighth-generation Camry built-in parts scale. In terms of the number of molds, it belongs to a relatively leading level in the industry.
After the mold is imported, various tests of local production will be carried out in accordance with the mass production standards, so that the new Camry high-strength steel special mold can stably produce high-quality plates.
In addition to the strength of the steel produced in its own factory, the eighth generation of the new Camry also uses 1500 MPa of thermoformed steel, which is provided by partner supplier Gestamp.
Due to the more complex body line design of the new eighth-generation Camry, the requirements for stamping body coverings will be much higher than those of previous stamping products. Among them, the requirements of side walls are the most complex, and they must ensure the accuracy of more than 2000 measurement points when stamping. (25mm for one measurement point)
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Introduction to welding workshop/painting workshop/final assembly workshop
Welding workshop:
The work of the welding workshop is mainly to assemble the stamping workshop production and supplier-supplied plates into a complete body-in-white.
The production line of the welding workshop mainly includes: floor line, side line, body general assembly line and body increase line.
In order to cope with the welding accuracy of the eighth-generation Camry's high-rigid body, 113 sets of high-speed robots, high-pressure welding guns, electrode head shaping machines, and new glue application robots have been added to the additional and total lines.
In order to ensure the quality of welding, this production line has introduced an electrical step head shaping robot, which will be repaired after each weld to ensure the state of the step head and the quality of each solder joint.
Compared with the traditional total destruction inspection, ultrasonic inspection improves the inspection efficiency, reduces the scrap rate of parts, and quantifies the strength of the solder joint from the data, providing data support for the strength guarantee of the whole vehicle.
In-line laser measurement is a technology currently used in most of the more advanced factories, and the TNGA production line is certainly no exception.
Laser online measurement, detection of the installation accuracy of each component of the body, to achieve instant accuracy detection function, mainly to measure the fender and the front door, front door and rear door, rear door and side of the gap and segment difference. It provides comprehensive, valuable data to analyze trends in body accuracy and nip poor quality in the bud.
Painting workshop:
The task of the painting workshop is to coat the white body completed by the welding workshop with layers of paint, in addition to strengthening the body rust, mainly to make the body look more beautiful. The painting process generally needs to go through cleaning, electrophoresis, color paint, varnish and other steps.
From pre-painting preparation to the completion of two-color body painting, there are more than 50 steps and an additional 165 minutes of production process than the normal version of the model, and the interface of the two colors needs to be checked in 30 minutes.
Final Assembly Workshop:
The final assembly workshop is the last workshop of production, where all the parts will be assembled, and the painted body will be assembled with the interior powertrain, chassis, etc. to form a complete car.
The assembly workshop includes three production lines: powertrain and chassis assembly line, interior assembly line and assembled powertrain, chassis and body assembly line.
This has higher requirements for the overall alignment accuracy of the equipment, which requires the relative angle deviation of the engine and the chassis to be less than 0.2 degrees, otherwise it cannot be installed. In order to achieve both quality and efficiency, the TNGA production line uses higher precision chassis switchers.
summary:
The unremitting pursuit of quality and rules and strict self-discipline have penetrated into the blood of GAC Toyota and are reflected in the daily details. Optimize processes in seconds and refine skills in microns. It is precisely by relying on such meticulous craftsmanship that in March 2018, two production lines of GAC Toyota were simultaneously evaluated as "zero defect rate" in Toyota's global quality control system. From 2015 to 2017, GAC Toyota's entire production line received the highest evaluation of "zero defect rate" for three consecutive years, setting a record for Toyota's overseas factories.
Today, GAC Toyota is striding towards a new peak of 800,000 units per year. "There is no best, only better" - this is not only the former's solemn commitment to 6 million car owners, but also conveys the sustainable development and continuous growth of the enterprise, and the confidence and confidence of going steady and far on the road of "craftsmanship casts good products, ingenuity quenches quality".
Article source: Network (such as intrusion and deletion)
Article Editor: Blean
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