Large amounts of spare parts made? Manufacturing process? Design differences?
In: Technology
My brother in law is a paint specialist at Toyota manufacturing in TX and I can tell you from listening to him for the years he’s been working there that their attention to detail is unlike anyone else. Kaizen, and other things mentioned here are spot on. He spent a couple years in Japan on rotational assignment and the processes there are the same as they are in TX. So, I’d say consistency in management, and continuity in production, are also contributing factors to Toyota quality. Fun bit: he was given millions of dollars to reduce the overspray (ie waste) in one of the paint processes, and he succeeding in doing so. So, consider the savings over time by reducing overspray by, say, 8% when you’re rolling a new vehicle off the line every 60 seconds or so (not sure of the exact “takt time” at present).
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