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TOYOTA MOTOR MANUFACTURING INDONESIATOYOTA MOTOR MANUFACTURING INDONESIATOYOTA MOTOR MANUFACTURING INDONESIATOYOTA MOTOR MANUFACTURING INDONESIA
JBIC Partnership Forum in AsiaJBIC Partnership Forum in AsiaSeminar onSeminar on
““GREEN MANAGEMENT & Corporate Competitiveness ~ Tradeoff or OpporGREEN MANAGEMENT & Corporate Competitiveness ~ Tradeoff or Opportunities ?tunities ?””
bybyHidematsuHidematsu Ibaragi (President Director)Ibaragi (President Director)
I Made Dana M.T (Senior General Manager)I Made Dana M.T (Senior General Manager)
Jakarta, November 4, 2008Jakarta, November 4, 2008
50 Year50 YearGolden YearGolden Year
Indonesia ~ Japan FriendshipIndonesia ~ Japan Friendship
TOYOTA WAY TOYOTA WAY
Contribution of COContribution of CO22 Reduction in Manufacturing & Logistic ActivitiesReduction in Manufacturing & Logistic Activitieson Environment Managementon Environment Management
1
TOYOTA MOTOR MANUFACTURING INDONESIATOYOTA MOTOR MANUFACTURING INDONESIA
Presentation OutlinePresentation Outline
1. INTRODUCTION1. INTRODUCTION……..........................................................................................................................................................................* TMMIN Company Profile & Product Line Up* TMMIN Company Profile & Product Line Up……………………………………………………………………....
2. TOYOTA POLICY ON ENVIRONMENT2. TOYOTA POLICY ON ENVIRONMENT………………………………………………………………..a. Toyota Global Visiona. Toyota Global Vision…………………………………………………………………………………………………………………………b. TMMIN Environment Action Plan (Focus Item)b. TMMIN Environment Action Plan (Focus Item)………………………………………………………………
3. IMPLEMENTATION OF TMMIN ENVIRONMENT ACTIVITIES.3. IMPLEMENTATION OF TMMIN ENVIRONMENT ACTIVITIES.> > COCO22 Reduction in Manufacturing & Logistic ActivitiesReduction in Manufacturing & Logistic Activities………………………………………………..
4. CONCLUSION4. CONCLUSION……………………………………………………………………………………………………………………………………..
2
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55
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PagePage
TOYOTA MOTOR MANUFACTURING INDONESIATOYOTA MOTOR MANUFACTURING INDONESIA
Head OfficeJl. Yos Sudarso, Sunter II, Jakarta
14330 Phone (62-21) 6515551
(hunting), Fax. (62-21) 6515360Total Employee 5,271 persons
Share HoldersToyota Motor Corporation (95%),
PT Astra International Tbk (5%)
Production FacilityProduction Facility
Sunter I Plant :
Engine Plant (13,000 Units/Month)Packing Plant (5000 Units/Month)
Sunter II Plant :Casting Plant (1,000 Tons/Month)Stamping Plant (8,000 Units/Month)U-IMV Packing Plant (4,200 Units/Month)
Karawang Plant :Integrated Mfg. FacilityStamping, Welding, Painting, AssemblingCAPACITY : 100,000 Units/Year AREA : Land 100 HA (Used 30 HA)AREA : Land 129,275 m2
AREA : Land 41,527 m2
1. INTRODUCTION1. INTRODUCTION
Company ProfileCompany Profile
3
TOYOTA MOTOR MANUFACTURING INDONESIATOYOTA MOTOR MANUFACTURING INDONESIA
2004 2005 2006 2007 2008
TMMIN Product Line UpTMMIN Product Line Up
Starting of Production Aug 2004
Starting of Production Oct 2006
Domestic & Export
Domestic & Export
Starting of Production June 2008
Domestic
4
TOYOTA MOTOR MANUFACTURING INDONESIATOYOTA MOTOR MANUFACTURING INDONESIA
Toyota Global Vision
Environmental Mission
Basic
Approach
1) Approach to Environment Issue
2) Approach to Business Process
The
Mos
t Ad
mire
d in
Wor
ld &
Regio
nal
Mon
ozuk
uri in
Harm
ony w
ith
Envir
onm
ent
• Glob
al W
arm
ing
•SOCs
• Nat
ure
Reso
urce
s
• Com
plian
ce w
ith R
egula
tion
• Hum
an R
esou
rces
Dev
elopm
ent
• Soc
ial C
ontri
butio
n
• Disc
losur
e of
Env
ironm
enta
l Inf
orm
ation
2. TOYOTA POLICY ON ENVIRONMENT2. TOYOTA POLICY ON ENVIRONMENT
a. Toyota Global Visiona. Toyota Global Visiona. Toyota Global Vision
5
TOYOTA MOTOR MANUFACTURING INDONESIATOYOTA MOTOR MANUFACTURING INDONESIA
Monozukuri means more than simply manufacturing products, but instead covers a set of activities and processes,
from development through production to sales and service, that create added value to fully satisfy our customers.
Cycles of NatureMonozukuri
in harmony with cycle of nature
Toyota Global VisionToyota Global Vision
6
TOYOTA MOTOR MANUFACTURING INDONESIATOYOTA MOTOR MANUFACTURING INDONESIA
Cycle of IndustryCycle of Industry
Service of Service of Social DevelopmentSocial Development
Toyota Global VisionToyota Global Vision
7
TOYOTA MOTOR MANUFACTURING INDONESIATOYOTA MOTOR MANUFACTURING INDONESIA
Ultimate Eco-CarUltimate Eco-Car
IssueIssue
IssueIssue
IssueIssue
Diesel enginesDiesel
enginesGasoline engines
Gasoline engines
Electrical energy
Electrical energy
Alternative fuel enginesAlternative fuel engines
Air quality issuesAir quality issues
Energy issuesEnergy issues
CO2 reductionCO2 reduction
BiofuelsBiofuels
Synthetic fuels
Synthetic fuels
DPNRDPNR
Common rail DICommon rail DILean burnLean burn
VVT-iVVT-iCNGCNGEVEV
D-4D-4
Hybrid TechnologyHybrid Technology
Diesel HVDiesel HV Plug-in HVPlug-in HVTHS IITHS II
FCHVFCHVAlternative
fuel HVAlternative
fuel HV
Hybrid technology boosts performance for all powertrain systems
Toyota Product DevelopmentToyota Product Development
8
TOYOTA MOTOR MANUFACTURING INDONESIATOYOTA MOTOR MANUFACTURING INDONESIA
Toyota Earth CharterToyota Earth Charter
3. Substance ofConcern
The Fourth Toyota Environm
ental Action Plan -
Energy/Global Warming
The Fourth Toyota Environm
ental Action Plan
Toyota Global Environment Action PlanToyota Global Environment Action PlanEnvironment Focus ItemEnvironment Focus Item
Reduce the discharge of substances (SoC)
Implement initiatives to reduce VOC emission
Disclosures of environmental information & two way communication
ManagementStrengthen consolidated environment management
1. Cooperation with Society
2. AtmosphericQuality
Reduction of Waste & Water
Substances ofSubstances ofConcernConcernSubstancesOf Concern
Substances ofSubstances ofConcernConcern
Recycling ofResources
4. Energy (Global Warming)
Reduce CO2 emissions in each country & region
: Focus Explanation
9
TOYOTA MOTOR MANUFACTURING INDONESIATOYOTA MOTOR MANUFACTURING INDONESIA
2. TOYOTA POLICY ON ENVIRONMENT2. TOYOTA POLICY ON ENVIRONMENT
b. TMMIN Environment Action Plan ( Focus Item)b. TMMIN Environment Action Plan ( Focus Item)b. TMMIN Environment Action Plan ( Focus Item)
4.Energy / Global Warming
4.Energy / Global Warming
3.Substance of Concern
3.Substance of Concern
RecyclingRecycling
EnvironmentalManagement
EnvironmentalManagement
Optimize reuse waterReduce water consumption & waste minimization
Reduce CO2 emission in manufacturing & logistic activities
Grasp CO2 data
ManufacturingManufacturing
LogisticLogistic
Eliminate SoC in Part (4 heavy metal parameter)SoC free for
Innova~FortunerSoC free for AvanzaInvestigation & switch over Follow up control &
regular audit
2.AtmosphericQuality
2.AtmosphericQuality
Reduce VOC (Volatile Organic Compound) from Painting processRecovery Thinner
1.CooperationWith Society
1.CooperationWith Society
Zero Emission Zero Emission Zero WasteZero Waste
Regional No.1Regional No.1Local No.1Local No.1
Alternative Energy Energy efficiency for process
Continuous improvement to reduce electric & fuel consumption (PDCA)
Fuel & truck efficiency Target Setting & PDCA
Packing materials reduction
Introduce ESG Incinerator top coat stack Water borne
Waste recycle (Hazardous) Continuous Cleaner Production
Implement ISO 14001 incorporated with Toyota Global EMS
CSR & Community Development Activities
2007 2008 2009 2010 2011
Oct.
Waste Water Management Soil & Air Pollution Environment Performance
10
TOYOTA MOTOR MANUFACTURING INDONESIATOYOTA MOTOR MANUFACTURING INDONESIA
3.1 Cooperation with Society3.1 Cooperation with Society
3. IMPLEMENTATION OF 3. IMPLEMENTATION OF TMMIN ENVIRONMENT ACTIVITIESTMMIN ENVIRONMENT ACTIVITIES
(Example & Focus Points)(Example & Focus Points)
3.3 Substance of Concern (3.3 Substance of Concern (SoCSoC))
3.4 Energy / Global Warming3.4 Energy / Global Warming
3.2 Atmospheric quality3.2 Atmospheric quality
11
TOYOTA MOTOR MANUFACTURING INDONESIATOYOTA MOTOR MANUFACTURING INDONESIA
Toyota Eco Youth Program Environmental Improvement Contest for Senior High School student
Scope : National (30 School, 13 Provinces)
Greenery Program Plantation in surrounding TMMIN Location : Karawang Residence
2. Perform TMMIN's concern and contribution to the country & societyObjective : 1. Empowerment Community Surrounding TMMIN business
Contribution to local communityBuild trust with local groupsPositive atmosphere
Example 1)Example 1) Example 2)Example 2)
3.1 Cooperation with Society3.1 Cooperation with Society
3. Implementation of TMMIN Environment Activities3. Implementation of TMMIN Environment Activities
Impact :
12
TOYOTA MOTOR MANUFACTURING INDONESIATOYOTA MOTOR MANUFACTURING INDONESIA
3. IMPLEMENTATION OF 3. IMPLEMENTATION OF TMMIN ENVIRONMENT ACTIVITIESTMMIN ENVIRONMENT ACTIVITIES
(Example & Focus Points)(Example & Focus Points)
3.3 Substance of Concern (3.3 Substance of Concern (SoCSoC))
3.4 Energy / Global Warming3.4 Energy / Global Warming
3.2 Atmospheric quality3.2 Atmospheric quality
3.1 Cooperation with Society3.1 Cooperation with Society
13
TOYOTA MOTOR MANUFACTURING INDONESIATOYOTA MOTOR MANUFACTURING INDONESIA
Reduce VOC (Volatile Organic Compound)
from Painting ProcessWhat is VOC ?What is VOC ?
(Impact of VOC)
Photochemical smog Suspended particulate matter
(SPM)
Respiratory illnesses
Painting Process
Photochemical smog Suspended particulate matter
(SPM)
Sunlight
VOC
Use of Solvents
Evaporated Organic Chemical
Paints & Coating
Improvement Example :Improvement Example :
TMMIN VOC (Emission) Reduction TMMIN VOC (Emission) Reduction AchievementAchievement
59.45
64.2167.16
Optimizing Paint Robot
Recovery Thinner
ApplicationElectronic Static
Gun
Incinerator for top coat stack
MajorActivity
Water borne
6865
60
5550
= Actual= Target
70
60
50
2006 2007 2008 2009 2010
gr / m2
Target
1. SURFACER ROBOT
2. CLEAR ROBOT
1. SURFACER ROBOT
2. CLEAR ROBOT
Optimizing use for Painting Robots
Tack Time ChangeVOC Reduction : 1.01 g/m2
Recovery Thinner
Change gravity to pump systemVOC Reduction : 3.09 g/m2
Application ESG (Electronic Static Gun)
ESG Application on Spray Clear (6 Guns)VOC Reduction : 1.22 g/m2
2006
3.2 Atmospheric quality3.2 Atmospheric quality
3. Implementation of TMMIN Environment Activities3. Implementation of TMMIN Environment Activities
2007
2008
14
TOYOTA MOTOR MANUFACTURING INDONESIATOYOTA MOTOR MANUFACTURING INDONESIA
3. IMPLEMENTATION OF 3. IMPLEMENTATION OF TMMIN ENVIRONMENT ACTIVITIESTMMIN ENVIRONMENT ACTIVITIES
(Example & Focus Points)(Example & Focus Points)
3.3 Substance of Concern (3.3 Substance of Concern (SoCSoC))
3.4 Energy / Global Warming3.4 Energy / Global Warming
3.2 Atmospheric quality3.2 Atmospheric quality
3.1 Cooperation with Society3.1 Cooperation with Society
15
TOYOTA MOTOR MANUFACTURING INDONESIATOYOTA MOTOR MANUFACTURING INDONESIA
Eliminate SoC in Part : Lead (Lead (PbPb)), Cadmium (, Cadmium (CdCd), ),
Progress Status 2007~2008
2 Companies(Remaining)
95 Companies(SoC
Free)
Total Parts (SoC)Total Suppliers (SoC)97 Companies
Bracket Exhaust TailBracket Exhaust Tail
BulbBulbStay Head RestStay Head Rest
Part Example :Part Example :
Before (Before (SoCSoC content)content) After (After (SoCSoC Free)Free)
CR CR 6+6+ CR CR 6+6+
PbPb, , CdCdCR CR 6+6+
3.3 Substance of Concern (3.3 Substance of Concern (SoCSoC))
3. Implementation of TMMIN Environment Activities3. Implementation of TMMIN Environment Activities
Mercury (Hg), Mercury (Hg), HexavalentHexavalent CromiumCromium (Cr6+)(Cr6+)
Target complete Dec 2009
On Progress20 partsAvanza2
as 1 Agt 2008SoC Free 100%130 partsInnova, Fortuner1
RemarkStatusTotal Part
(SoC content)VehicleNo
Target complete Dec 2009
On Progress20 partsAvanza2
as 1 Agt 2008SoC Free 100%130 partsInnova, Fortuner1
RemarkStatusTotal Part
(SoC content)VehicleNo
130 Parts(SoC
Free)
20 PartsAvanza
InnovaFortuner
2009
16
TOYOTA MOTOR MANUFACTURING INDONESIATOYOTA MOTOR MANUFACTURING INDONESIA
3. IMPLEMENTATION OF 3. IMPLEMENTATION OF TMMIN ENVIRONMENT ACTIVITIESTMMIN ENVIRONMENT ACTIVITIES
(Example & Focus Points)(Example & Focus Points)
3.3 Substance of Concern (3.3 Substance of Concern (SoCSoC))
3.4 Energy / Global Warming3.4 Energy / Global Warming
3.2 Atmospheric quality3.2 Atmospheric quality
3.1 Cooperation with Society3.1 Cooperation with Society
17
TOYOTA MOTOR MANUFACTURING INDONESIATOYOTA MOTOR MANUFACTURING INDONESIA
TMMIN CO2 Reduction ActivitiesTMMIN COTMMIN CO2 2 Reduction ActivitiesReduction Activities
Reduce CO2 emissionsManufacturing
Reduce CO2 emissionsManufacturing Reduce CO2 emissions
LogisticReduce CO2 emissions
Logistic
Internal LogisticInternal Logistic External LogisticLogistic
External LogisticLogistic
3.4 Energy / Global Warming3.4 Energy / Global Warming
3. Implementation of TMMIN Environment Activities3. Implementation of TMMIN Environment Activities
AA BB
B1B1 B2B2
b. Packing Container Efficiency Upb. Packing Container Efficiency Up
a. Local Parts Delivery Systema. Local Parts Delivery System
18
TOYOTA MOTOR MANUFACTURING INDONESIATOYOTA MOTOR MANUFACTURING INDONESIA
FY 2007 ~ 2008 : Utilization of alternative energy
CO2 reduction : 274 ton CO2 / Month
Total Invest :Rp. 11.5 Billion
Future Activity :> Improve process for energy efficiency
Cost reduction : Rp. 1,4 Billion/MonthReturn on Investment : 9 Months
CO2 GeneratedTon COTon CO22 /Unit/Unit
as Sept ’0
8
‘‘0606 ‘‘0707 ‘‘0808 ‘‘0909 ‘‘1010
0.30.3
0.20.2
0.40.4
0.50.5
0.60.6Reduction Target 15%
TargetTarget
YearYear
0.48
0.45 0.43 0.414
0.407
A. COA. CO22 Reduction in Manufacturing ActivitiesReduction in Manufacturing Activities
3. Implementation of TMMIN Environment Activities3. Implementation of TMMIN Environment Activities
Replacement of Diesel Oil with Natural Gas
19
TOYOTA MOTOR MANUFACTURING INDONESIATOYOTA MOTOR MANUFACTURING INDONESIA
TMMIN CO2 Reduction ActivitiesTMMIN COTMMIN CO2 2 Reduction ActivitiesReduction Activities
Reduce CO2 emissionsManufacturing
Reduce CO2 emissionsManufacturing Reduce CO2 emissions
LogisticReduce CO2 emissions
Logistic
Internal LogisticInternal Logistic External LogisticLogistic
External LogisticLogistic
3.4 Energy / Global Warming3.4 Energy / Global Warming
3. Implementation of TMMIN Environment Activities3. Implementation of TMMIN Environment Activities
AA BB
B1B1 B2B2
b. Packing Container Efficiency Upb. Packing Container Efficiency Up
a. Local Parts Delivery Systema. Local Parts Delivery System
20
TOYOTA MOTOR MANUFACTURING INDONESIATOYOTA MOTOR MANUFACTURING INDONESIA
PRODUCTION LINE
Lead Time (L/T)
CO2 CO2
Supplier Store
TMMIN
Volume(Stock, Space)
OthersOthers
OperatorOperator
TowingTowing
ForkliftForklift
OthersOthersOperatorOperator
TowingTowing
ForkliftForklift
OthersOthersOperatorOperator
TowingTowing
Time
Volume& L/T
REDUCE VOLUME & LEAD TIME
REDUCE VOLUME & LEAD TIME
BASIC THINKING
ForkliftForklift
B1. COB1. CO2 2 Reduction in Internal Logistic ActivitiesReduction in Internal Logistic Activities
MachineMachine
ManManCOST
REDUCTIONCOST
REDUCTIONCO2
REDUCTIONCO2
REDUCTION
by 4 M Analysis(Man, Machine,
Material, Method)
21
TOYOTA MOTOR MANUFACTURING INDONESIATOYOTA MOTOR MANUFACTURING INDONESIA
REDUCE FORKLIFT OPERATION at ENGINE PLANT LOGISTIC SYSTEMREDUCE FORKLIFT OPERATION at ENGINE PLANT LOGISTIC SYSTEM
START
START
- TOWING A = FILL IN LOCAL PART
- TOWING B = FILL IN IMPORT & SUPPLYRemarks : = Area Forklift
SUB MAIN LINE
BIG PART AREA
CY
LIN
DE
R H
EA
D M
AC
HIN
ING
LIN
E
CR
AN
KS
HA
FTM
AC
HIN
ING
LIN
E
CA
M S
HA
FT
MA
CH
ININ
G L
INE
WAITING LANE
PROGRESS LANEAREA
1
2
3
4
5
6
8
9
10
11
12
BP
EMPTY STORE
EMPTY STORE
KANBAN ROOM
SHORTAGE TANK
RECEIVING 1 E
OASIS ASSY TR
TEST BENCH TR
EMPTY BOX READY DELIVERY TO SUPPLIER
RECEIVING CHECK
RECEIVING CHECK
PART DEFFECTAREA
FINISH GOOD ENGINE
PACKING AREA
DELIVERY KARAWANG
PREPARE ENGINE
CY
LIN
DE
R B
LOC
K
MA
CH
ININ
G
LIN
E
RECEIVING CHECK
RECEIVING CHECK
RECEIVING 1 F
EMPTY PALLETAREA
OASIS LOGISTIC
TR
ASSY LINE TR
COLLECT AREA
RECEIVING CHECK
RECEIVING CHECK
RECEIVING CHECK
RECEIVING CHECK
P3A P3A P3A P3A P3A P3A P3A27 26 25 24 23 22 21
AREA TRAINNING CENTER
KANBAN ROOM
TEMPORARY AREA
P2A P2A P2A P2A P2A P2A P2A P2A20 19 18 17 16 15 14 13
P1A P1A P1A P1A P1A P1A P1A P1A P1A P1A P1A11 10 9 8 7 6 5 4 3 2 1
PALLET SAFETY STOCKMACHINING PART
UNBOXING AREA
PALLET SAFETY STOCKMACHINING PART
OVER FLOW
BP
BPBP BP BP
BP
BP
77 6
FREE LOCATION RACK
FREE LOCATION RACK
M0051 O K
M
M121 M126 J004 M125 J016
M121 M126 J004 M125 J016
P1B07
P1B08
P1B09
P1B10
P1B11
P1B12
P1B15
P1B14
J020
J020M18AM18BM18CJ023J011J076J040
M18AM18BM18CJ023J011J076J040
O K M
M010
M009
TRANSITAREA
BIG PART AREA
P3A P3A P3A P3A P3A P3A P3A27 26 25 24 23 22 21
P2A P2A P2A P2A P2A P2A P2A P2A20 19 18 17 16 15 14 13
P1A P1A P1A P1A P1A P1A P1A P1A P1A P1A P1A11 10 9 8 7 6 5 4 3 2 1PC STORE AREA
M0051 O K
M
M121 M126 J004 M125 J016
M121 M126 J004 M125 J016
P1B07
P1B08
P1B09
P1B10
P1B11
P1B12
P1B15
P1B14
J020
J020M18AM18BM18CJ023J011J076J040
M18AM18BM18CJ023J011J076J040
O K M
M010
M009
A
A
AA
PC STORE AREA
PC STORE AREAPC STORE AREA
BB
BP
ASSY LINE TR
BP
BPBP BP
B
B
B
BEFORE AFTER
1) Productivity :Space Reduction for Forklift Operation : 334 m2Forklift Reduction : 1 Unit
2) Safety : Reduce potential forklift (car) accident3) Environment : CO2 Reduction : 230 Kg/Day4) Cost : Reduction : Rp. 72,000/Day
FORKLIFT SPACE : 2,154 m2 FORKLIFT : 3 Units COST/DAY : Rp. 216,000 CO2 : 690 Kg/Day
FORKLIFT SPACE : 2,154 m2 FORKLIFT : 3 Units COST/DAY : Rp. 216,000 CO2 : 690 Kg/Day
: Forkliftless: Forklift need
START
START
- TOWING A = FILL IN LOCAL PART
- TOWING B = FILL IN IMPORT & SUPPLYRemarks : = Area Forklift
SUB MAIN LINE
BIG PART AREA
CYL
IND
ER
HEA
D M
AC
HIN
ING
LIN
E
CR
ANK
SHAF
TM
ACH
ININ
GLI
NE
CAM
SH
AFT
M
ACH
ININ
G L
INE
WAITING LANE
PROGRESS LANEAREA
1
2
3
4
5
6
8
9
10
11
12
BP
EMPTY STORE
EMPTY STORE
KANBAN ROOM
SHORTAGE TANK
RECEIVING 1 E
OASIS ASSY TR
TEST BENCH TR
EMPTY BOX READY DELIVERY TO SUPPLIER
RECEIVING CHECK
RECEIVING CHECK
PART DEFFECTAREA
FINISH GOOD ENGINE
PACKING AREA
DELIVERY KARAWANG
PREPARE ENGINE
CY
LIN
DER
BLO
CK
M
AC
HIN
ING
LI
NE
RECEIVING CHECK
RECEIVING CHECK
RECEIVING 1 F
EMPTY PALLETAREA
OASIS LOGISTIC
TR
ASSY LINE TR
COLLECT AREA
RECEIVING CHECK
RECEIVING CHECK
RECEIVING CHECK
RECEIVING CHECK
P3A P3A P3A P3A P3A P3A P3A27 26 25 24 23 22 21
AREA TRAINNING CENTER
KANBAN ROOM
TEMPORARY AREA
P2A P2A P2A P2A P2A P2A P2A P2A20 19 18 17 16 15 14 13
P1A P1A P1A P1A P1A P1A P1A P1A P1A P1A P1A11 10 9 8 7 6 5 4 3 2 1
PALLET SAFETY STOCKMACHINING PART
UNBOXING AREA
PALLET SAFETY STOCKMACHINING PART
OVER FLOW
BP
BPBP BP BP
BP
BP
77 6
FREE LOCATION RACK
FREE LOCATION RACK
M0051 O K
M
M121 M126 J004 M125 J016
M121 M126 J004 M125 J016
P1B07
P1B08
P1B09
P1B10
P1B11
P1B12
P1B15
P1B14
J020
J020M18AM18BM18CJ023J011J076J040
M18AM18BM18CJ023J011J076J040
O K M
M010
M009
TRANSITAREA
BIG PART AREA
P3A P3A P3A P3A P3A P3A P3A27 26 25 24 23 22 21
P2A P2A P2A P2A P2A P2A P2A P2A20 19 18 17 16 15 14 13
P1A P1A P1A P1A P1A P1A P1A P1A P1A P1A P1A11 10 9 8 7 6 5 4 3 2 1PC STORE AREA
M0051 O K
M
M121 M126 J004 M125 J016
M121 M126 J004 M125 J016
P1B07
P1B08
P1B09
P1B10
P1B11
P1B12
P1B15
P1B14
J020
J020M18AM18BM18CJ023J011J076J040
M18AM18BM18CJ023J011J076J040
O K M
M010
M009
A
A
AA
PC STORE AREA
PC STORE AREAPC STORE AREA
BB
BP
ASSY LINE TR
BP
BPBP BP
B
B
B
Utilize Towing or Manual Handling
Internal Logistic Improvement ExampleInternal Logistic Improvement Example
FORKLIFT SPACE : 1,820 m2 FORKLIFT : 2 Units COST/DAY : Rp. 144,000 CO2 : 460 Kg/Day
FORKLIFT SPACE : 1,820 m2 FORKLIFT : 2 Units COST/DAY : Rp. 144,000 CO2 : 460 Kg/Day
22
TOYOTA MOTOR MANUFACTURING INDONESIATOYOTA MOTOR MANUFACTURING INDONESIA
TMMIN CO2 Reduction ActivitiesTMMIN COTMMIN CO2 2 Reduction ActivitiesReduction Activities
Reduce CO2 emissionsManufacturing
Reduce CO2 emissionsManufacturing Reduce CO2 emissions
LogisticReduce CO2 emissions
Logistic
Internal LogisticInternal Logistic External LogisticLogistic
External LogisticLogistic
3.4 Energy / Global Warming3.4 Energy / Global Warming
3. Implementation of TMMIN Environment Activities3. Implementation of TMMIN Environment Activities
AA BB
B1B1 B2B2
b. Packing Container Efficiency Upb. Packing Container Efficiency Up
a. Local Parts Delivery Systema. Local Parts Delivery System
23
TOYOTA MOTOR MANUFACTURING INDONESIATOYOTA MOTOR MANUFACTURING INDONESIA
TMMIN’s Logistics Supply Chain
TMMINProduction Plant
Import Parts(MSP/JSP)
Local Supply Parts(LSP)
Importer
Main Distributor
Export Port
EXTERNAL LOGISTICSEXTERNAL LOGISTICSCO2
CO2 CO2
CO2
CO2
B.2aB.2b
Port
Lead Time (1)Lead Time (2)
Volume
Tact Time :Working Hours
No. of Production/Sales
B2. a. CO2 Reduction in External Logistic ActivitiesB2. a. CO2 Reduction in External Logistic Activities
Part, StockPart, Stock
Operator /Driver
Operator /Driver
Truck Efficiency
Truck Efficiency
Time
Volume& L/T
MachineMachine
by 4 M Analysis(Man, Machine,
Material, Method)
ManMan
MaterialMaterialPart, StockPart, Stock
Operator /Driver
Operator /Driver
Truck Efficiency
Truck Efficiency
Part, StockPart, Stock
Operator /Driver
Operator /Driver
Truck Efficiency
Truck Efficiency
Part, StockPart, Stock
Operator /Driver
Operator /Driver
Truck Efficiency
Truck Efficiency
Time
Volume& L/T
MachineMachine
by 4 M Analysis(Man, Machine,
Material, Method)
ManMan
MaterialMaterialPart, StockPart, Stock
Operator /Driver
Operator /Driver
Truck Efficiency
Truck Efficiency
Part, StockPart, Stock
Operator /Driver
Operator /Driver
Truck Efficiency
Truck Efficiency
BASIC THINKING
Container efficiencyPart Module
Container efficiencyPart Module
Operator /Driver
Operator /Driver
Truck Efficiency
Truck Efficiency
Time
Volume& L/T
MachineMachine
by 4 M Analysis(Man, Machine,
Material, Method)
ManMan
MaterialMaterial Container efficiencyPart Module
Container efficiencyPart Module
Operator /Driver
Operator /Driver
Truck Efficiency
Truck Efficiency
Container efficiencyPart Module
Container efficiencyPart Module
Operator /Driver
Operator /Driver
Truck Efficiency
Truck Efficiency
Container efficiencyPart Module
Container efficiencyPart Module
Operator /Driver
Operator /Driver
Truck Efficiency
Truck Efficiency
Time
Volume& L/T
MachineMachine
by 4 M Analysis(Man, Machine,
Material, Method)
ManMan
MaterialMaterial Container efficiencyPart Module
Container efficiencyPart Module
Operator /Driver
Operator /Driver
Truck Efficiency
Truck Efficiency
Container efficiencyPart Module
Container efficiencyPart Module
Operator /Driver
Operator /Driver
Truck Efficiency
Truck Efficiency
REDUCE VOLUME(Truck Efficiency, Lot)
& LEAD TIME
(Waiting time, Stagnant time, etc)
REDUCE VOLUME(Truck Efficiency, Lot)
& LEAD TIME
(Waiting time, Stagnant time, etc)
COST REDUCTION
COST REDUCTION
CO2 REDUCTION
CO2 REDUCTION
Same Same ConceptConcept
24
TOYOTA MOTOR MANUFACTURING INDONESIATOYOTA MOTOR MANUFACTURING INDONESIA
= TMMIN Direct Supplier= TMMIN Milkrun Supplier
TANGERANG
SUNTER
BEKASI
CIBITUNG/CIKARANG
KARAWANG/CIKAMPEK
BOGOR
TMMIN LOCAL SUPPLIER MAPTruck Transportation ( Example )Truck Transportation ( Example )
25
TMMIN
TMMIN
TOYOTA MOTOR MANUFACTURING INDONESIATOYOTA MOTOR MANUFACTURING INDONESIA
LOCAL PARTS DELIVERY SYSTEMLOCAL PARTS DELIVERY SYSTEM
TMMINTMMINCikarang
Cibitung
33 Km
36 Km
39 Km
29 Km28 Km
25 Km
TMMINTMMINCikarang
Cibitung
46 Km
33 Km
6 Delivery/Day, 190Km 2 Delivery/Day, 79Km
Before : Direct Delivery After : Grouping Delivery
40800
41600
42400
43200
Before After
1,128 Km/day
8800
9600
10400
Before After
23
24
25
26
27
28
Before After
Distance ReductionDistance Reduction
Fuel ReductionFuel Reduction
CO2 Emission ReductionCO2 Emission Reduction
262 L/day
68O Kg/day
Karawang Plant Karawang Plant
TOTAL ACHIEVEMENT UP TO SEPT 2008
42,560
41,433
9,874
9,613
25.9 25.2
Empty Space
Empty Space
Loading Efficiency : 89%
External Logistic Improvement ( Example )External Logistic Improvement ( Example )
26
TOYOTA MOTOR MANUFACTURING INDONESIATOYOTA MOTOR MANUFACTURING INDONESIA
TMMIN’s Logistics Supply Chain
TMMINProduction Plant
Import Parts(MSP/JSP)
Local Supply Parts(LSP)
Importer
Main Distributor
Export Port
EXTERNAL LOGISTICSEXTERNAL LOGISTICSCO2
CO2 CO2
CO2
CO2
B.2aB.2b
Port
Lead Time (2)
Volume
Part, StockPart, Stock
Operator /Driver
Operator /Driver
Truck Efficiency
Truck Efficiency
Time
Volume& L/T
MachineMachine
by 4 M Analysis(Man, Machine,
Material, Method)
ManMan
MaterialMaterialPart, StockPart, Stock
Operator /Driver
Operator /Driver
Truck Efficiency
Truck Efficiency
Part, StockPart, Stock
Operator /Driver
Operator /Driver
Truck Efficiency
Truck Efficiency
Part, StockPart, Stock
Operator /Driver
Operator /Driver
Truck Efficiency
Truck Efficiency
Time
Volume& L/T
MachineMachine
by 4 M Analysis(Man, Machine,
Material, Method)
ManMan
MaterialMaterialPart, StockPart, Stock
Operator /Driver
Operator /Driver
Truck Efficiency
Truck Efficiency
Part, StockPart, Stock
Operator /Driver
Operator /Driver
Truck Efficiency
Truck Efficiency
BASIC THINKING
Container efficiencyPart Module
Container efficiencyPart Module
Operator /Driver
Operator /Driver
Truck Efficiency
Truck Efficiency
Time
Volume& L/T
MachineMachine
by 4 M Analysis(Man, Machine,
Material, Method)
ManMan
MaterialMaterial Container efficiencyPart Module
Container efficiencyPart Module
Operator /Driver
Operator /Driver
Truck Efficiency
Truck Efficiency
Container efficiencyPart Module
Container efficiencyPart Module
Operator /Driver
Operator /Driver
Truck Efficiency
Truck Efficiency
Container efficiencyPart Module
Container efficiencyPart Module
Operator /Driver
Operator /Driver
Truck Efficiency
Truck Efficiency
Time
Volume& L/T
MachineMachine
by 4 M Analysis(Man, Machine,
Material, Method)
ManMan
MaterialMaterial Container efficiencyPart Module
Container efficiencyPart Module
Operator /Driver
Operator /Driver
Truck Efficiency
Truck Efficiency
Container efficiencyPart Module
Container efficiencyPart Module
Operator /Driver
Operator /Driver
Truck Efficiency
Truck Efficiency
REDUCE VOLUME(Truck Efficiency, Lot)
& LEAD TIME
(Waiting time, Stagnant time, etc)
REDUCE VOLUME(Truck Efficiency, Lot)
& LEAD TIME
(Waiting time, Stagnant time, etc)
COST REDUCTION
COST REDUCTION
CO2 REDUCTION
CO2 REDUCTION
Same Same ConceptConcept
B2. b. Packing Container Efficiency UpB2. b. Packing Container Efficiency Up
27
TOYOTA MOTOR MANUFACTURING INDONESIATOYOTA MOTOR MANUFACTURING INDONESIA
Before : Direct Delivery After : Milk Run Delivery
86%
94%
82%
84%
86%
88%
90%
92%
94%
96%
B efore A fter
ACHIEVEMENT UP TO SEPT 2008
CONTAINER EFFICIENCYCONTAINER EFFICIENCY
0
20
40
60
80
100
Before After
NUMBER OF CONTAINERNUMBER OF CONTAINER
20 Cont./day
Trucking : 3150 Kg/DayShipping (130 Ton/Cont):
674,700 Kg/Day
COCO22 EMISSION REDUCTIONEMISSION REDUCTION
PACKING CONTAINER EFFICIENCY UP (CKD Export to Philippine)PACKING CONTAINER EFFICIENCY UP (CKD Export to Philippine)
TMMINPacking
EMPTY SPACE
Importer
54 Container/Day66 Container/Day
TMMINPacking Importer
NO EMPTY SPACE
Packing Improvement ExamplePacking Improvement Example
0
28
TOYOTA MOTOR MANUFACTURING INDONESIATOYOTA MOTOR MANUFACTURING INDONESIA
4. Conclusion4. Conclusion1. Environment conservation is important to be done to save the earth &
as corporate social responsibility (CSR)
2. Environment management activities aligned with company goal to reduce cost and increase efficiency
3. To achieve cost reduction & CO2 reduction in manufacturing and logistic activities, it will maximize achievement of corporate competitiveness
29
TOYOTA MOTOR MANUFACTURING INDONESIATOYOTA MOTOR MANUFACTURING INDONESIA30
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