Bidai, Karnataka
Company Overview
Toyoda Gosei - Bidadi: Located in Bidadi, Karnataka, the Toyoda Gosei facility is a vital component of the global Toyoda operation. Toyoda Gosei specializes in the manufacturing of automotive components, with a specific focus on bumpers and airbags. These components are not only critical for the safety of the vehicles but also contribute significantly to the overall aesthetics of the cars they are designed for. Toyoda Gosei has established a reputation for producing high-quality components, especially for vehicles like the Toyota Crysta Innova, Toyota Hycross Innova, and Toyota Fortuner.
The company also plays a pivotal role in the automotive industry by providing safety system (SS) products, such as airbags, not only to Toyota but also to other prominent automakers like Maruti Suzuki India Ltd. (MSIL), Renault, and Nissan. This further demonstrates Toyoda Gosei's significance in promoting road safety through the supply of critical safety components.
Executive Summary
Our field visit to Toyoda Gosei's facility in Bidadi, Karnataka, offered a comprehensive understanding of the company's operations, emphasizing safety, efficiency, and innovation. The visit provided a glimpse into the best practices that have made Toyota a global leader in the automotive industry, highlighting the successful adoption of Japanese management principles and techniques in an Indian context.
Visit Overview
Faculty Co-ordinator – Dr. Udaya Shankar
Phase 1 - Learning Area Visit
During the initial phase of the visit, our team was led by Mr. Bhanuprakash and Mr. Lokesh. They introduced us to Toyoda Gosei's training programs, namely Gurudhama and Dojo. Gurudhama, launched in June 2017, is a 15-day training program that combines five days of classroom training with ten days of hands-on experience. This comprehensive training approach ensures that employees have both the theoretical knowledge and practical skills required for their roles.
Toyoda Gosei has also instituted an innovative approach to safety training. They've created a chart of unsafe methods and working conditions, accompanying it with images illustrating the potential consequences in extreme cases. This serves as a powerful visual reminder to employees of the importance of following safety protocols.
The facility also employs a Personal Protective Equipment (PPE) matrix, which outlines safety parameters for different job roles on-site, including Injection Moulding jobs and the Paint Shop. Waste segregation is another critical aspect, with different colored bins for different types of waste, making it easy for employees to dispose of waste responsibly.
Notably, the concept of the "knowledge cage" stands out as a unique approach to employee development. Here, employees spend 15 minutes studying a topic of their choice, demonstrating a commitment to ongoing learning. Additionally, the "Who is responsible for your safety?" cupboard, with a mirror inside, reinforces the principle that individual employees are ultimately responsible for their own safety.
Phase 2 - Shopfloor Visit
In the second phase of our visit, Mr. Vinod Kumar guided us through the shop floor. The importance of safety was underscored as we were required to wear safety gear, including hats and safety shoes, before entering the production area.
The primary products manufactured by Toyoda Gosei include bumpers and airbags. The products are supplied not only to Toyota vehicles but also to other automakers, such as Maruti Suzuki India Ltd. (MSIL), Renault, and Nissan.
We had the opportunity to visit three plants, with plants 1 and 2 focusing on molding processes, while plant 3 specializes in the manufacturing of bumpers and houses heavy machinery equipment.
The emphasis on lean manufacturing is evident in the facility's inventory management. Toyoda Gosei maintains a stock of only 0.5 days' worth of inventory, which highlights their commitment to just-in-time production and waste reduction.
Robotic automation is another striking feature of the facility, especially in the paint area, where robots handle the paint job. This is a clear testament to the company's commitment to advanced manufacturing technologies.
The application of Japanese management concepts, such as JIT, 5S, Kaizen, Hiyarihatto (sensing potential danger and taking actions beforehand), and 4M (Man, Machine, Material, Method), underscores the commitment to operational excellence.
Key Observations & Insights
· Safety Emphasis: Toyoda Gosei's unwavering commitment to safety is demonstrated through its comprehensive training programs, safety parameters, and visual reminders of the potential consequences of unsafe practices.
· Efficiency and Precision: The facility's minimal inventory and adoption of Kanban and TPS reflect an operational focus on efficiency, precision, and waste reduction.
· Japanese Management Concepts: The incorporation of JIT, 5S, Kaizen, and other Japanese management principles signifies a commitment to continuous improvement and excellence in operations.
· Innovation: The use of advanced technology, such as robotic automation and innovative machines like KARAKURI, illustrates the company's dedication to staying at the forefront of manufacturing technology.
· Cultural Diversity: The facility's diverse workforce, primarily from Karnataka, reflects a harmonious blend of cultures and demonstrates the effectiveness of Toyoda Gosei's global management approach.
· Food Arrangements: The organization's approach to providing food for employees with shared costs emphasizes a sense of community and care for the workforce.
Conclusion
The field visit to Toyoda Gosei, Bidadi, offered an invaluable opportunity to witness firsthand the company's dedication to safety, operational excellence, and innovation in the manufacturing of critical automotive components. The successful integration of Japanese management principles into an Indian context and the emphasis on safety as a core value is inspiring. Toyoda Gosei's operations exemplify the harmonious synergy between Japanese automotive excellence and Indian manufacturing capabilities. Our visit has provided profound insights into the world of automotive manufacturing and has been both enlightening and inspirational for our team of operations management students.
