Improving a Comprehensive Kaizen Strategy at an Engine Factory: Focusing on Workforce, Expenses, and Sustainability

Toyota's Kamigo Plant Embraces Innovation and Sustainability

Toyota's engine plant in Kamigo, Toyota City, Aichi Prefecture, has been making significant strides in production and sustainability. As of 2021, the plant produces 1.33 million engine units annually, catering to a broad range of engines from 1.5L units to 3.5L units.

One of the plant's latest initiatives is the production of 1 million cylinder heads for TNGA engines, a testament to its commitment to cutting-edge technology. This production line, known as the SS Line, was established in 2013 to provide a workplace for rehired elderly workers, without relying on physical strength or electricity.

The SS Line employs the philosophy of kaizen, a continuous improvement approach that Toyota has long embraced. A recent kaizen initiative has eliminated the need for missing washers on head bolts, preventing potential mistakes. The line also utilises karakuri mechanisms, which move by using the weight of objects, allowing veteran workers to fully utilise their skills and knowledge.

In terms of sustainability, the plant has been making concerted efforts to reduce CO2 emissions. Since 2017, the plant has been producing engines based on the Toyota New Global Architecture (TNGA). Improvements in the casting process have reduced annual CO2 emissions by approximately 1,800 tons. The change to the binding agent used in core production has also significantly reduced emissions. The amount of smoke generated is now 1/100th of previous levels, and odours are 1/115th.

The adoption of new regeneration furnaces to recycle sand has further contributed to the plant's carbon footprint reduction. Each line reduces annual CO2 emissions by 45 tons. These efforts have resulted in an annual reduction of approximately 1,800 tons of CO2 at Kamigo Plant alone.

Moreover, Toyota's global Kaizen initiatives for carbon neutrality involve employees at all levels, management teams, suppliers, and local communities. At the Kamigo Plant, major initiatives include energy efficiency improvements, waste reduction programs, and the adoption of renewable energy technologies implemented over recent years. The plant has even brought forward the target timing for plant carbon neutrality from 2050 to 2035.

The plant's focus on sustainability is evident in other aspects as well. Raw materials account for one-quarter of emissions among all Toyota plants. However, the change in materials has made the working environment at Kamigo Plant more comfortable, with the need for masks no longer necessary.

The SS Line also prioritises worker comfort and safety. It improves the view by adjusting the heights of chutes so that everyone can see each other's faces and by using coverless equipment and machinery. There are always up to three highly skilled technicians stationed on the line to oversee operations and make improvements to any work processes that appear to be causing difficulty.

The SS Line's layout is planned and setup by "highly skilled technicians" from various divisions at the plant, with jigs and tools arranged in a way that facilitates line operation. This meticulous planning ensures smooth production and a comfortable working environment for the plant's 3,441 employees.

In conclusion, Toyota's Kamigo Plant is a testament to the company's commitment to innovation and sustainability. The plant's continuous improvement efforts, focus on worker comfort, and dedication to reducing CO2 emissions make it a shining example of Toyota's philosophy of kaizen connecting to carbon neutrality initiatives.

Improving a Comprehensive Kaizen Strategy at an Engine Factory: Focusing on Workforce, Expenses, and Sustainability