TOYOTA DO BRASIL Vinicius Albert Sabin Contadini Soares Strategic Planning & Administration of Public Relations & Government Affairs
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1 TOYOTA DO BRASIL Vinicius Albert Sabin Contadini Soares Strategic Planning & Administration of Public Relations & Government Affairs
2 AGENDA Toyota Global Toyota do Brasil Toyota Way Our Priorities Case: Environmental Project at Sorocaba plant Other cases and Sustainability Report
3 1. TOYOTA GLOBAL
4 1. TOYOTA GLOBAL 70 Plants Employees 9,1 Million Vehicles sold in 2015
5 2. TOYOTA DO BRASIL
6 2. TOYOTA DO BRASIL 59 5,6 YEARS IN BRAZIL EMPLOYEES THOUSAND UNITS 180 SALES 8,8% MARKET SHARE
7 4. TOYOTA WAY
8 4. TOYOTA WAY Challenge Kaizen Genchi Genbutsu Continuous Improvement Respect For People Respect Teamwork
9 6. OUR PRIORITIES
10 6. OUR PRIORITIES Timing Cost Volume Quality Safety & Environment
11 7. CASE ENVIRONMENTAL PROJECT AT SOROCABA PLANT
12 7. CASE ENVIRONMENTAL PROJECT CO2 EMISSION REDUCTION
13 7. CASE ENVIRONMENTAL PROJECT 01 Sorocaba Plant 02 Environmental Award TDB won a Brazilian National Award with Conservation and Reuse of Water, in Green Area (Morizukuri) 04 Production Details Etios Sedan & HB Export to: Argentina Uruguay Honduras We have more than 80 thousand trees in Green Area Zone. Prod. capacity: 108K Employees: ~ 1900 Peru Paraguay Costa Rica
14 7. CHALLENGE TOYOTA ENVIRONMENTAL CHALLENGE 2050
15 7. CASE ENVIRONMENTAL PROJECT Env. KPI CO 2 above of target at FY14 CO 2 EMISSION (kg/veh) FY13 FY14 71
16 7. CASE ENVIRONMENTAL PROJECT kg CO 2 /veh Sorocaba plant target FY13 (RESULT) Result FY14 (RESULT) Target FY15 (TARGET) How can we achieve the target?
17 7. CASE ENVIRONMENTAL PROJECT Energy Quantity How works the ABCD concept? A = The ideal energy used according production. A A B = Energy used for production (Along the shift). It is the ABCD Concept. A C B C D D D D D E 1º Shift 2º Shift B Comp. Air Feeder. B C C = Energy used to start/finish the production. D = Energy to keep some process and security. C D Carrier is only used in production time. The screwdriver is only used when you need in production. The boiler needs pre-warm to achieve the ideal Temperature. Some light are working 24h per day. 0 h Star t En d 24 h 0 h Star t En d 24 h 0Star h t En d 24 h 0 h 24 h
18 7. CASE ENVIRONMENTAL PROJECT ABCD Concept Training How to use the ABCD Concept? ABCD! Strong Teamwork A W T P We will not give up! Let s work together!!! Too difficulty to implement!!!
19 7. CASE ENVIRONMENTAL PROJECT 1 Classification Rank Up 2 - Reduce into category Our goal is to rise the equipment to A! Use energy only at productive time REDUCE (SAVING)! Saving energy, reducing the category of ABCD A B C D A B C D
20 7. CASE ENVIRONMENTAL PROJECT ABCD Concept implementation 1 Equipment s map 2 Quantity of equipment Lets investigate! A B C D Σ = 809 We classified each equipment according to ABCD Activity start We found a lot of KAIZEN s opportunities! How can we Start!?
21 7. CASE ENVIRONMENTAL PROJECT
22 7. CASE ENVIRONMENTAL PROJECT ABCD KAIZEN EXAMPLES 1 - What is RTO? 2 - How does it work? VOC Treated Air BOOTH: NO VOC EMISSION OVEN: VOC EMISSION RTO: TREATS THE AIR Natural Gas is used to heat the system The Regenerative Thermal Oxidizer (RTO) oxidizes and decomposes Volatile Organic Compounds (VOCs) and odorous emissions discharged from paiting process 3 ABCD Classification OVEN RTO 5:50 Oven s Preparation RTO s Preparation Oven s Operation RTO Operation 6:00 7:40 01:37 Start of Production End of Production A B C D C
23 7. CASE ENVIRONMENTAL PROJECT 1 Before Situation (Cause Analysis) APPLIED ABCD CONCEPT -> RECOGNIZED MUDA! RTO C RTO B 2 PDCA Activities 1 st : Studying the working time of the equipment. 2 nd :Tests to start the equipment later. 4:20 Too Early 5:00 Too Early 6:00 Too Early 7:20 Ok 7:30 Too Late We learned that the RTO needs 20 min to be ready! RTO Star t Production Start First body enter Oven Let s change RTO start to 7:20 AM! Ok, let s do ABCD kaizen! 5:50 6:00 7:40 3 After Situation (Start 7:20am) 4 - Results REDUCTION OF 1:30h RTO C REDUCED!!! Productio n Start *NEW * RTO Start MUDA of Natural Gas have been eliminated RTO C First body enter Oven RTO B Almos t Rank B SAVING! Almost B Class! A B C D Reduction: 1.65 kg CO 2 /Veh. 5:50 6:00 7:20 7:40 Reduced 1:30 hour
24 7. CASE ENVIRONMENTAL PROJECT 1 - What is the Cooling Tower? 2 - How does it work? Cooling Tower Cooling Tower Cold Water Hot Water 23 C Welding Shop 31 C 3 ABCD Classification Cooling Tower function: Reduce temperature of equipment at Welding Shop. 0h Cooling Tower s period operation 24 hr/day Production time Production time 24h D
25 7. CASE ENVIRONMENTAL PROJECT 1 Before Situation (Cause Analysis) 2 PDCA Activities (ABCD CONCEPT) MUDA! IDEA PROPOSAL COMMENT EVALUATIO N Andon Panel Cooling Tower Cooling Tower B Production 1 st Shift Cooling Tower B Production 2 nd Shift CURRENT 1 2 TURN OFF MANUALLY (RULE) AUTOMATED TURN OFF SYSTEM PEOPLE USED TO FORGET THE EQUIPMENT WORKING HIGH COST Connection cable ENERGY B ENERGY D 3 CONNECT COOLING TOWER TO ANDON PANEL EFFICIENT-LOW COST Cooling Tower 3 After Situation 4 - Results Cooling Tower Now, the Cooling Tower works only during production time. Cooling Tower B ENERGY B Cooling Tower B ELIMINATED ENERGY D CURRENT ABCD RANK UP! A B C D Reduction: 0.04 kg CO 2 /Veh
26 7. CASE ENVIRONMENTAL PROJECT SUMMARY STRATEGY DESCRIPTION TEAM WORK
27 7. CASE ENVIRONMENTAL PROJECT - RESULTS Equip. Qty 1 Total ABCD Rank up Result D C B A ABCD Rank up Overview BEFORE AFTER BEFORE AFTER x A B C D 1x 9x 13x
28 7. CASE ENVIRONMENTAL PROJECT - RESULTS kg CO 2 /Veh 1 - CO 2 Emission Reduction Result Reduced 8 kg CO 2 /Veh Target Result FY13 FY 14 Others ABCD FY Result
29 7. CASE ENVIRONMENTAL PROJECT - STANDARDIZATION 1 Standardization WHAT? WHEN? WHERE? WHO? WHY? HOW? Steps to use ABCD concept END FY15 TDB - SOR ESCO TEAM Developing new ideas of kaizen to reduce the CO 2 emission and YOKOTEN to other TDB plants. Running PDCA 2 nd cycle 2 Payback, Yokoten and Next Steps KAIZEN Inv. (R$) PAYBACK YOKOTEN NEXT STEPS Time (month) SOR Other Plants ABCD 2 nd Cycle 1 RTO T C. Tower W Subcomponents of the equipment are the focus now.
30 7. CASE ENVIRONMENTAL PROJECT - YOKOTEN 4 Training ABCD Concept (YOKOTEN INFO SHARING) SOR Pioneer in TDB IDT SBC PFZ
31 8. SUSTAINABILITY REPORT
32 8. SUSTAINABILITY REPORT MORE CASES /sustentabilidade
33 THANK YOU
34
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