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August 17, 2012. Energy Huntsville Forum. 1. CAPTIN 1985. TMMC 2 2008. TMMC 1988. SIA 2007. TEMA 1996. TMMWV 1998. TMMI 1999. BODINE 1990. TABC 1971. TMMK 1988. BODINE 2005. TMMAL 2003. TMMBC 2004. TMMMS 2011. TMMTX 2006. $21+ Billion Invested 40,000 Direct Employees. - PowerPoint PPT Presentation
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August 17, 2012
1
Energy Huntsville Forum
TABC 1971
CAPTIN 1985
TMMK1988
TMMC 1988
BODINE1990
TEMA1996 TMMWV
1998TMMI1999
TMMAL2003TMMBC
2004
TMMTX 2006
SIA 2007
TMMC 2 2008
BODINE2005
$21+ Billion Invested
40,000 Direct Employees
TMMMS2011
Toyota Manufacturing in North America
Vehicle Plants - 7
Unit Plants - 5
Engine Plants - 2
Regional HQ
2
TMMAL Overview – Company Profile
3
Foundation: June 1, 2001
Investment: $700 million (by Spring 2014)
Location: Huntsville, AL
Plant Size: Land 200 acres Building 1.08 million sq ft
4-Cyl4.0L V-6
5.7L & 4.6L V-8
Toyota Property Line
Employees: 1,150 (by Spring 2014)
Engines 1GR E/G ( V6 4.0L ) 3UR E/G ( V8 5.7L ) &1UR E/G (V8 4.6L)
1AR FE ( 2.7L ) &2AR FE (2.5L)
Capacity 146,000/yr 144,000/yr 216,000/yr
SOP Aug. '05 Dec. '06 (3UR), March '09 (1UR) Sept. '11
Stats 24 valve 245 HP32 valve 381 HP /
32 valve 310 HP16 valve 182 HP / 16 valve 178 HP
Customers TMMBC, TMMTX TMMI, TMMTX TMMK, TMMC, TMMI, SIA
NEW 3.5L V-6
What Makes Toyota Different?
4
• Empower Team Members
• What Gets Measured Gets Done
• Never Stop Improving
TMMAL Environmental Team
What is the Environmental Team?
5
• Provides support, guidance and standardization
• Team Member-driven Environmental system/program
• Follows annual calendar for activities, training and audits
Who is on the Environmental Team?
• Voluntary position• 2 per Group House – 1 per shift• Serve at least one year, many
serve longer if trained as Internal Environmental Auditor
Regular Environmental Activities
6
Process Checks DAILY
Kamishibai Checks WEEKLY
Team, Management Meetings
MONTHLY
Audits SEMIANNUAL
Kaizen Blitz SEMIANNUAL
Daily Process Checks
7
• Production Team Members check their process daily at start and end of shift
• Report any issues or concerns for compliance or risk
• Enables management, Environmental Team Members to quickly address issues and implement countermeasures
Right: Mist Collector Machining Process
Below: Daily Checksheet
Kamishibai Checks
8
• Use card system and board for audit tracking
• Environmental Team completes weekly audit on all items in daily checks
– Managing your process– Compliance and risk– Knowledge retention
• Ensures production Team Members are completing daily checks accurately
紙芝居 = “paper drama”
•Form of Japanese storytelling
•Often shared with elementary-age children
Team & Management Meetings
9
• Monthly Team meeting to:– Share targets and results– Communicate new requirements– Highlight special events
• Provide monthly status update to upper management, address any specific issues raised in Monthly Team Meeting
Semiannual Environmental Audits
10
• Specially-trained group of auditors within Environmental Team
• Conduct semiannual audits to confirm system health. Look for:
– Compliance and risk management– Training records and document control
• Face-to-face interviews with randomly selected team members on environmental awareness topics
• Auditors responsible for multiple areas in plant, but can’t audit own area
Semiannual Kaizen Blitz
11
KAIZEN – Continuous Small Improvement
BLITZ – Hitting it from all directions in a concentrated effort!
Cross functional team focuses on improvements in specific environmental impact areas:
– Energy– Water– Waste– Special Projects
Semiannual Kaizen Blitz
12
• Corporate offices provide target reduction percentage, TMMAL calculates identified savings for next year
• Potential kaizens placed on following FY’s Environmental Management Plan
– TMMAL currently working on items identified in FY12
Semiannual Kaizen Blitz
13
FY12 Energy Reduction
1,069,5321,175,400
0
200,000
400,000
600,000
800,000
1,000,000
1,200,000
1,400,000
Target Actual
Kil
ow
att
Ho
urs
123,662 kwh, $8,656 annual savings by replacing outside lighting
283,500 kwh, $19,845 annual savings using compressed air actuators in production areas
Semiannual Kaizen Blitz
14
Compressed Air Actuators13 valves not being
used in production areas• 63 hours/week• Estimated Annual Savings:
– 283,500 kwh/year– $19,845 / year
Semiannual Kaizen Blitz
15
Outdoor Lighting• Switch outside HPS lighting to
UCD Lighting• Reduces energy usage by 70%• Total of 100 pole lights
Cost = $23,993
Savings = $8,656 / yr
Payback = 2.75 yrs
Energy Reduction = 123,662 kwh/yr
Old
New
Semiannual Kaizen Blitz
16
FY12 Water Reduction
411,000
655,000
0
200000
400000
600000
800000
Target Actual
Ga
llo
ns
630,000 gallons saved using Nano Filtration system to recover 70% of lost water
Semiannual Kaizen Blitz
17
6/7 cycles
1/7 cyclesNano Filter
History• Average Summer monthly
usage = 1,000,000 gallons• Average waste = 150,000
gallons
Projected• 70% of lost water will be
saved with filter • 105,000 gallons will be
put back in system
Semiannual Kaizen Blitz
18
FY12 Waste Reduction
27,000
62,000
0
10000
20000
30000
40000
50000
60000
70000
Target Actual
Kil
og
ram
s
More than $70,000 savings identified through improved waste recycling opportunities
Semiannual Kaizen Blitz
19
Covanta Go-and-See• Environmental Team Members
visited Covanta site• Potential Items to be recycled:
– Cardboard– Plastic– Paper– Parts– Dunnage
• Target 50% of load diverted to recycle stream
Driver left debris when leaving compactor
Summary
20
• Empower Your Team Members
• What Gets Measured Gets Done
• Never Stop Improving
Any questions?
21