This article is a writeup on Toyota's Indian operations and how Toyota is planning to make the Bidadi plant (click here for the video on how Toyota Etios is being made) as one of it's top production sites in the world.
Toyota Automobiles, Japan started manufacturing operations in India as a collaborative effort with Kirloskar in 1997 in India in Bidadi, near Bangalore, Karnataka. The first vehicle of the Qualis brand, a Multi-Use-Vehicle (MUV), rolled out by 2000. Qualis was a runaway success for Toyota in India. It was so popular, that this initial high quality manufacturing pitch prepared the right environment and acceptance among Indians of Toyota quality and great Toyota vehicles to be introduced in India.
The following steps will demonstrate the commitment by the management of Toyota Japan through this plant of Toyota in India to ensure high standards of environmental consciousness practiced in the plant. As claimed by Toyota Bidadi, this is one of the most advanced plants of Toyota in the world and includes great environmental sustainability and solar energy initiatives in the plant. Toyota Kirloskar Motors (TKM) Bidadi, India produces only 3,20,000 cars annually, producing 3 % of its global production.
First let us start with some of the great environmental and social steps initiated by Toyota which have been initiated in India, along with some of the other production sites in Japan.
Monozukiri - manufacturing in harmony with the environment has been the guiding light behind Toyota's environmental sustainability initiatives.
Environmental Sustainability initiatives :
|A view of final assembly line, courtesy Malayala Manorama.|
5. Reducing CO2 emissions - Using route optimisation, the supply of spare parts to the various distribution centres across the country using LCVs having only 20% space utilisation was shifted to smaller vehicles ensuring 80% space utilisation. This helped TKM save 10.3 T of CO2 emission and saving INR 3,00,000 a year.
6. The bio-gasifier plant inside the factory premises handles daily 1.5 tonnes of food waste generated in the TKM canteen and converts it into 100-120 cu.m of biogas, a non-polluting renewable source of energy, saving 40-50 kg of LPG consumption a day and generating app 140 kg of solid manure daily used in the gardens..
7. Use of racks from suppliers while supplying spare parts reduces packaging.- Toyota may the first in the country to use this unique style of taking delivery of items from suppliers. Usually spare parts come in paper or plastic packaging and once the parts are used in the assembly the packing material is waste that needs to be properly reused, recycled or destroyed. Toyota has come up with the unique method where by the suppliers are sent spare parts racks by Toyota which are filled by the suppliers and sent to Toyota. After the spare parts are used, these empty racks are again sent to the suppliers who fill them and return it to Toyota with new spare parts. The cycle continues saving large amounts of waste packing materials.
8. Toyota is the first company in India to use water based paints : the company was the first to use water based paint, even though it was costlier, it is environment friendly. Volatile organic compounds (VOC) that float around in the paint shop as the paint solvent vapourises, is a major health hazard. Water based paints are a great initiative from Toyota to reduce VOC emissions and build healthy workplaces.
9. Planting 2.5 lakh saplings inside the 432 acres Bidadi campus of TKM has helped bring back green cover and oxygen.
All Toyota cars came with dual air bags across all models, with 100 per cent anti-lock braking system and was awarded four star in the Global NCAP crash test.
Social initiatives :
12. Toyota Technical Training Institute (TTTI) - established in 2007 as part of Toyota's Corporate Soial Responsibility Initiative (CSR) about 40 selected students after their 10th or 12th are given intense training for almost three years before they are inducted into the Toyota production line.
The unique nature in which Toyota differs from the rest oif the manufacturing world is the way in which they plan their manufacturing. While usually organisations make a demand forecast and try to plan to meet this demand, Toyota is one of the few companies in the world that manufactures to meet customer demand.
Click for my earlier writings on Toyota , Ten points to some great learning and the other one on Lean Manufacturing at Toyota Bidadi ..
Bidadi plant of Toyota has an annual capacity of assembling 3,20,000 vehicles, though it is still pain as Toyota still imports the engine, power transmission and gear box from plants around the world as they are not yet sure whether the workforce in India would be able to match up with the high standards of quality and excellence attained by Toyota around the world. This also partly explains why, after importing automobile components taking up almost 70% value of the final automobile, Toyota is not able to gets its cars on Indian roads at less than Rs 7 lakhs on-road price, while other low end Japanese, German, Korean and French manufacturers like Honda, Suzuki, Volkswagen, Renault, Hyundai are able to offer cars at less than or near about Rs 5 lakhs.
1. Toyota Kirloskar takes steps to reduce vehicle CO2 emissions, The Hindu, Business, 28 Dec 2016
PS - 1. the author teaches Lean Manufacturing at Alliance University, Bangalore, India. He can be reached at firstname.lastname@example.org
2. Technological Innovation especially in energy area has helped India advance in critical areas of energy application. India's advanced expertise in the solar technology application area cannot be demonstrated any better than with the help of the world's first and only 100% solar energy powered, energy neutral International airport, a super critical application, fully functional and operational in Kochi, Kerala, India (the third largest airport in the country with 1.5 million sq ft area handling 9 million passengers annually) for the past twenty months without occurence of any accident or untoward event. Click for the link here...