Recently, the chief technician of Wuzheng Group went to Japan Toyota Motor, and other companies, to study lean management and efficient production. The 7th Chief Technician of Wuzheng Group, and 28 exemplary employees of Wuzheng Takakita Company, embarked on the study project.
The first stop of the seminar was the Toyota Park Town factory. The production mode here is deeply shocking. Error prevention systems, such as the warning light pick-up rack and the torque wrench alarm, are everywhere. The self-improving synchronous tool cart
The first stop of the seminar was the Toyota Park Town factory. The production mode here is deeply shocking. Error prevention systems, such as the warning light pick-up rack and the torque wrench alarm, are everywhere. The self-improving synchronous tool cart can follow the movement of the staff, and after the completion of the operation, it can automatically return to its original position. The employee training field can exercise the flexibility and accuracy of the employee's movements in the form of games, so that each employee can develop accurate and correct job operations, and good working habits, through training. The lubricating parts of the fork truck are good, and the complete handover record table is attached. As music cues the rest time, all work lights are extinguished. 100% of the people go out and the lights turn off. The production is strictly in accordance with the order. The car uses water to make fuel, achieve zero pollution and so on. The chief technicians also went to the Toyota Hall to learn about Toyota's lean manufacturing concept, zero-emissions of the factory, production automation and other high-end manufacturing technologies, and visited the Toyota main models.
The second stop of the seminar was the headquarters of the Takakita Company and the neighboring Yasunaga Company.
At the Takakita Company, the trainees watched Takakita’s presentations video and visited Takakita’s bearing processing plant and agricultural machinery factory. Takakita's bearing processing plant mainly processes bearings for order from other companies. The factory has a laboratory with a constant temperature of 22 °C to test the processed parts. The warehouse of Takakita Headquarters adopts the mode of code scanning. The material handler will scan the material code every time when taking the parts, and the warehouse data is updated in real time. The agricultural machinery factory applies four major processes; stamping, welding, painting and assembly. Although there are many materials and equipment, they are well organized and the space utilization rate is very high. The material warehouse is in good order.
The trainees also exchanged ideas with Takakita engineers on thin-plate welding deformation prevention measures, stamping scratch prevention, steel sheet springback, heat treatment cracks and other issues. Through communication, the trainees deeply felt the craftsmanship of Japanese employees. They will test, collect and save data before designing stamping and welding parts. In the design, the deformation factors and parameters will be considered to avoid deformation after processing. The use of other processes to minimize the use of stamping and welding processes will be considered. They are precautionary to prevent abnormalities rather than repair abnormalities after processing.
