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Agenda
• Introductions• Business Conditions• Toyota Transformation
– TNGA, Reborn, NA1T– Process/Collaboration Reform
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TTC Purchasing/SED/Cost Planning
Robert YoungGroup Vice President
Noby TanakaExecutive Advisor
Mak TakekawaVice President
Seiya NakaoPresident, TTC
Direct & Manufacturing
Indirect Purchasing
Cost Planning
Supplier Engineering Development
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TTC Purchasing/SED/CPD OrganizationDeb
Schroeder
Seats, Interior &
Exterior
Jamie Todd
Powertrain,Chassis
& Functional
Greg Laskey
Electronics, Electrical &
Body
Jason Reid
Materials &Indirect
Jim Holloway
Supplier Relations, Diversity, Risk Mgt.,
& Systems
Ryan Grimm
Project Mgmt.,Service &Export
Eric Doll
SED I
Chris Kostopoulos
SED II
BrianJordan
SED III
Luc Zilio
SED V
KimEngel
SED IV
Dave Girvan
Cost Planning
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Introduction
Adam KaribianVice President, Vehicle Monozukuri& Data MgmtSr. Executive Engineer –Body DesignToyota Technical Center, York Township, MI
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Agenda
• Introductions• Business Conditions• Toyota Transformation
– TNGA, Reborn, NA1T– Process/Collaboration Reform
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2015 ReflectionVehicle Production
2011 2012 2013 2014 2015
Production
Capacity Increases 2015 Toyota Sales
2015 Industry Sales2M
Vehicle YearCapup amount
Comment
Tacoma 2015 +30K TMMBC shift pattern
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2015 Reflection
GR Kai
New Launches Next Gen TNGA Development
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2016 and Beyond
10.4 11.6 12.814.5 15.6 16.5 17.5
2009 2010 2011 2012 2013 2014 2015 2016 2017
VOLUME UNCERTAINTY
ADJUST PRODUCTION MIX TO MARKET
49.4% 51.1% 50.0% 48.2%43.2% 41.1%
50.6% 48.9% 50.0% 51.8%56.8% 58.9%
30.0%
40.0%
50.0%
60.0%
70.0%
11CY 12CY 13CY 14CY 15CY 16CYTD
LV Sales % of TotalCar Truck
Leveling Market
Prepare for next downturn
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2016 and Beyond Development & Production Preparation (TNGA Deployment)
TMMGT Preparation
Early SourcingSienna
HighlanderTrucksEngines
Guanajuato, MXCorolla, 2019
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Midterm Challenges & Opportunities
New Entrants New Mobility Models Hardware ‐> Software Value
Future Mobility: Conventional Mobility:
Strong Competitive Landscape: Marketability Quality Active Safety Fuel Economy Mass Reduction Fleet Optimization
Global Cost Competitiveness
80+% of Mix for Foreseeable Future Change Point/Opportunity Prep
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Agenda
• Introductions• Business Conditions• Toyota Transformation
– TNGA, Reborn, NA1T– Process/Collaboration Reform
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"Sudden and drastic changes in the business environment means that conventional ways of thinking and doing business can no longer help us grow sustainably. We are at a crossroads where we must now build a new business model.”
Toyota TransformationThe Need for Change
13
Making Better Cars Through TNGA
Akio Toyoda
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Collaboration Reform
Toyota Transformation
Safety Quality MonozukuriMfgr. Optimization
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Collaborative Advanced Development: Linking Design and Manufacturing
Innovation to develop the best next generation platform/series/family solutions.
Frontload Collaboration
Toyota’s New Global ArchitectureTNGA
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Manufacturing ReBORN: Footprint Alignment
• First launch of TNGA in NA
• Maximize family development
• Centralize midsize production close to OEM supply base
• Enhance flexibility to the market
• Corolla #1 selling compact car –2014
• Re‐alignment of supply chain center of gravity to the South
• Continue to align supply chain for Tacoma parts
• Implement mid‐term strategy to meet customer demand and maintain flexibility
ReBORN
Ever Better Cars Optimize Vehicle& Location
Stable Growth & Competitiveness
Mid‐sized Small Truck
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ReBORN: Ever Better PlantsReBORN
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NA1T ‐ One Toyota Streamline Decision Making
Integrate Regional Functions
Strengthen Midterm/Long Strategic Planning
Enhance Development thru Colocation
Accelerate Innovation
NA1T
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NA1T StructureNA1T
Jim LentzCEO, NA
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Plano UpdateNA1T
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Georgetown Update
TMMK
NA1T
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York UpdateNA1T
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NA1T
Prototype Building
4th Qtr 2016
York Co‐locationDesign / Collaborate / Trial
Supplier Center1st Qtr 2017
(E3) Engineering Design Building
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Collaboration Reform
Co‐LocationNew
Organizational Structure
Process Reform‐ Safety‐ Quality‐ Manufacturing
Optimization‐ Advanced
Development
Pur & SED• Increased headcount• Reduced Span of
Control• Alignment with Design
Divisions
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Workplace Safety
Process Score
TIR Result
Process Reform
Link Collaboration with Risk
Objective: Continuous Improvement
Actions based on Risk Assessment
Total Incident Rate DataProcess Self Assessment Update Annually
Output: ‐Trend Data (Process and Result) ‐Focused Activity for Common Areas of Improvement‐Increased Best Practice Sharing‐Go & See to support Process Kaizen
Low Medium High
Process Risk
HH
ML MM MH
LM
High
Medium
Low LH
HM
Results
Risk
HL
LL
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Quality Collaboration Process Reform
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Quality CollaborationAnnual Quality Business Meeting (AQBM), May 2016
Purpose and Intent• Share Quality Priorities & New Initiatives• Strengthen Collaboration & Best Practice Sharing• Strengthen Continuous Improvement for Quality
Award Winner Board Display (Best Practice Sharing) AQBM Meeting Q&A Panel
Reactive Proactive
Process Reform
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Manufacturing OptimizationGoal: Continuous Benchmark & Improvement
Benchmarking Problem Solving Kadai (ideas)Yamazumi
Poor Line Balancing
Standard Work Flow
Supply Chain Mapping
Rate & Usage
Process Reform
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COMMODITYNEW SUPPLIER CENTER
VEHICLENEW VEHICLE MONOZUKURI CENTER
Advanced Development Collaboration
• Frontload Collaboration• Ensure One Voice
Monozukuri:The Art, Science & Craft of making things (mono: thing made, zukuri: act of making).
‐ Technology & processes integrating development, production & procurement targeting quality and continuous improvement.
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Commodity Development CollaborationCommodity Reform
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Advanced Commodity CollaborationExamples
Des
ign
Before After
Proc
ess
Optimal Design
25% more efficient process
Focused Team Collaboration
Scope
2
3020
40
FY14 FY15 FY16 FY17
Commodity Reform
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Obeya Reform Vehicle Reform
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Commodity Vehicle
K4 SE Genzu CVModAdvancedStage
ObeyaCommodity WG Kobeya
Find and Fix Process during Drawing Stage – Catch Issues Pre‐Release – Reduce ECIs
Appearance study confirmed by Rapid P, Functional study confirmed by Machined Parts
Enhance Obeya with Physical Parts Enhance Utilization of CV
Use all CV to evaluate specification differences and variations
Strengthen development using physical parts.
Enhance Prototype Quality
Make decisions with all stakeholders present using Rapid Prototype and prototype parts.
Within Obeya/Kobeyanew 3D Printer
Obeya/Kobeya Reform
Catch issues during DRW stage based on Physical Materials (RP and Proto Parts)
Vehicle Reform
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Engineering Building Purchasing Building
3rd Floor Obeya 1st Floor Supplier Center
C/F Kobeya‐ Design‐ Purchasing/SED‐ Suppliers‐ Prototype Division
‐ QE‐ NAMC
Kobeya
Obeya moves to PD Building
at CV
Kobeya Reform Vehicle Reform
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SED Frontloading
• Risk Assessment (Product, Process, Capability – All Tiers)• Drawing Review for Manufacturability• Process Planning Support• DR Activity (Risk Identification) & Recurrence Prevention• Cost Engineering Support• Joint Design Feedback/Negotiation
Strengthen TNGA Risk & Change Point Assessment Frontload Collaboration & Link with Family Development Strengthen Systems, Capacity and Capability
Vehicle Reform
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Collaboration Reform
Toyota Transformation
Safety Quality MonozukuriMfgr. Optimization
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The Toyota Way Purchasing Principles Collaboration
Kaizen
GenchiGenbutsu
Challenge
Teamwork
Respect
Kaizen
GenchiGenbutsu
Challenge
Teamwork
RespectRespectfor People
Continuous Improvement
Strengthen our Foundation
We Can Only Succeed Together
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THANK YOU