Founded in 2004, GAC Toyota is a joint venture between Guangzhou Automobile Group Co., Ltd. and Toyota Motor Corporation of Japan. The company is located in Nansha District, Guangzhou, the geometric center of China's vibrant Pearl River Delta.
As the Pearl River Delta region with the fastest pace of life and the most developed economy in China, consumers have very high requirements for quality, and GAC Toyota cars can be seen everywhere. It can be said that the local people have considerable trust in the cars produced by GAC Toyota.
In the "Toyota Global Delivery Quality Inspection" held in March last year, the vehicle quality of GAC Toyota's two production lines achieved "zero defective rate" (Toyota's term is "zero defective rate"), which is unique in the industry. Why is the vehicle quality of GAC Toyota so high? Perhaps, no matter how good things are, they are not as convincing as you see. Only by going deep into the workshop of GAC Toyota can we find out.
1003 day-this is the latest record of "zero water leakage" activity in the process of challenging sealant project of GAC Toyota painting.
65438+1On October 6th, GAC Toyota held the "One-day Craftsman" quality open day. The painting workshop has reached the challenge of "zero water leakage" for 1000 days, which has become the latest witness of GAC Toyota's "ingenuity".
The bulletin board at the door of the painting workshop clearly shows the record of "zero water leakage" since 1003 days, and this record is still going on. This record can be maintained because of the core of GAC Toyota's quality management-the concept of "self-process completion" and the responsibility spirit of "picking bones from eggs".
It seems to be a simple gluing action, but in order to ensure the quality of gluing, the craftsmen on the sealant line must practice at least 3500 times before taking up their posts, and they must be guided by special personnel before taking up their posts. They must realize that 3000 vehicles in a row are defect-free before they can work independently.
In the sealant production line of the painting workshop, workers hold a small and exquisite "cosmetic mirror" to confirm the sealing condition inside the car body through mirror reflection. It turns out that there is a point on the roof that is concave, in the blind area of vision. Pinholes are easy to occur when applying sealant, which leads to water leakage.
Zou, an employee of the painting workshop, said: "There were two defects a few years ago, which were detected during the test in the rain room. Later, we came up with this method and confirmed it through a mirror to ensure that no flaws were missed. "
On the production line, these gadgets created by workers and designed by them have really played a very practical role in production.
Guangzhou Automobile Toyota Painting Workshop is the first workshop in Toyota's global factory to cancel the intermediate painting inspection. The cancellation of this link not only saves 12 man-hours during intermediate coating inspection, but also saves the energy consumption of dozens of electric lamps during inspection. Ingenious workers use their own patented gadgets to eliminate the phenomenon of paint dripping in the spraying process, and also omit the work link of intermediate coating inspection, effectively avoiding the occurrence of "defective rate", which has to be said to be a pioneering work of GAC Toyota craftsman spirit.
Through these inventions to improve efficiency, in May last year, Zhongtu Workshop kept the quality stable by improving the quality in the manufacturing process, which was completely independent of the inspection line. It is understood that at present, the defect rate of GAC Toyota painting workshop is 3.6 defects per thousand vehicles, which is lower than one-fifth of the industry average (20 defects per thousand vehicles) and is at the top level in the world.
GAC Toyota's "self-process completion" concept and ingenuity also require upstream suppliers to do it at the same time and eliminate every "bad" in every basic link. In Guangzhou Yingtai, the interior supplier of GAC Toyota, the employees in the leather inspection post are also very vicious, and you can almost see where a piece of leather comes from at a glance.
Every piece of cowhide sent here has to undergo complicated and strict screening and selection before it can enter the production line: the belly and neck of the cow will be removed first because it is easy to wrinkle, the leather on the hoof will be removed because it is not soft and comfortable, and only the leather on the back of the cow will be adopted because it is exceptionally smooth and soft.
Guangzhou Yingtai has a special innovation studio, in which there is a complete sewing machine next to 100 disassembled sewing machine parts. Wang Langchao, a senior craftsman in the sewing department, said that the sewing of car seats has an important influence on the texture, so Guangzhou Yingtai requires the sewing error of seats to be controlled within1mm.
Wang Langchao found that if the original presser foot of sewing machine is not paid attention to when sewing, it is easy to have crooked snake defects. After many attempts, she developed a presser foot with a groove to fix the zipper, which reduced the snake defect to zero. At present, this invention has applied for a patent.
"Everyone guarantees quality in their own process and then creates all craftsmen." In the open quality class, Zou Dao, the head of the process completion promotion section of GAC Toyota Quality Management Department, gave the password of GAC Toyota's "ingenuity".
Zou introduced that "just-in-time" and "self-destruction" are the two pillars of Toyota's lean production model. "punctuality" avoids waste and improves efficiency; The "self-cleaning" with herringbone pattern next to it requires process quality assurance, so that people and machines can judge the process quality, find problems in time and improve them, and the defective products will not flow to the next process. And "self-discipline" should be realized through the working method of "self-process completion", which is also the core of quality management of GAC Toyota.
In order to completely realize the end of self-process, employees of GAC Toyota need to constantly learn and improve the conditions of products through repeated work, improve their work skills through mentoring and long-term tempering, and ensure that they can fully abide by the conditions of good products. Let everyone judge the process quality, become a craftsman in his post, ensure the quality in the process and challenge zero defects.
It is this cultivation of craftsmen's ingenuity that makes the quality of the whole vehicle of GAC Toyota's two production lines achieve "zero defective rate", which not only ensures the quality, but also lays a good foundation for the development of GAC Toyota in 20 17 years.
From the early days when Camry led the benchmark in the mid-level car market to the current shortage of Highlander cars, GAC Toyota has accumulated the reputation of "good products" every time it goes offline. The new factory to be put into production will not only ensure the supply of GAC Toyota to the market, but also continue to maintain the "zero defective rate" result. Guangzhou Automobile Toyota's concept of "self-process completion" plays a very important role in building craftsmen and cultivating ingenuity, which is bound to make a great contribution to the quality of Guangzhou Automobile Toyota, and all this done by Guangzhou Automobile Toyota will eventually benefit the consumers of Guangzhou Automobile Toyota.