The Toyota Quality Division involves various inspection cells, that check certain parts of the manufactured vehicle.

1. Toyota Motor Company Australia
Case study
ATS Inspect
02/11/2009
Page 1
Case Study - ATS Inspect - Toyota Australia www.ats-global.com

2. TMCA Requirements & Goals
Record every single defect
Report defects discovered back to responsible area
– real time
Inform Quality Managers when serious issues arise
(email / SMS)
Reduce number of defects
Improve Straight Through Ratio (Vehicles without
defects)
Remove paper where possible
Provide KPI reporting to the plant floor
02/11/2009
Page 2
Case Study - ATS Inspect - Toyota Australia www.ats-global.com

3. Toyota - Inspect Solution
02/11/2009
Page 3
Case Study - ATS Inspect - Toyota Australia www.ats-global.com

4. Defect Inspection Stations
The Toyota Quality Division involves
various inspection cells, that check
certain parts of the manufactured
vehicle.
Drum test
Wheel Alignment
Shower
Customer Satisfaction
Upon vehicle entering the inspection
cell:
Operator scans the barcode VIN
(Vehicle Identifier Number)
On ATS Inspect that unique
vehicle appears
Quality operator inspect part(s)
The defects found are recorded in
ATS Inspect by touch screen clicks
02/11/2009
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Case Study - ATS Inspect - Toyota Australia www.ats-global.com

5. Defect Repair Stations (Hanedashi)
Any vehicle with defects that can not
be repaired in the Inspection
Station is moved to the Hanedashi
area (repair area).
Upon vehicle entering the repair cell:
Operator scans the barcode VIN
(Vehicle Identifier Number)
ATS Inspects displays a list of all
vehicles recorded for that unique
vehicle.
Operator repairs defect(s)
Operator marks defects as
repaired in ATS Inspect.
02/11/2009
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Case Study - ATS Inspect - Toyota Australia www.ats-global.com

6. Plant floor Andon Board
Plant floor Andon boards are used
to feed back any quality issues
real time to quality operators.
ATS Inspect database structure
allows for reporting in any form
required.
Reported KPI’s include:
Straight Through Ratio (STR)
per inspection cell
Average number of defects
caused by manufacturing area
Top 5 defects recorded,
providing the defect, part,
location, quantity and
responsible area
02/11/2009
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Case Study - ATS Inspect - Toyota Australia www.ats-global.com

7. Assembly Control Room – Wall Projector
Provide Real Time feedback on
large projector screens in the
assembly control room, by
utilising custom made
Advanced Inspect Reports.
This allows for immediate
reaction on any rising issues or
‘trends’.
Defects caused by Assembly
lines and it’s Target for current
shift. [Top graphs]
Defected vehicles by
inspection cell for current shift
[Bottom left]
Straight Through Ratio by
assembly line and by plant
[Bottom right]
02/11/2009
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Case Study - ATS Inspect - Toyota Australia www.ats-global.com

8. Impact of Inspect
Operator
ATS Inspect ATS Inspect Steady decline
Training
Implementation in use in defects
Period
The total number of defects discovered on all vehicles inspected in the
02/11/2009 QDC area (by month). Steady decline of number of defects.
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Case Study - ATS Inspect - Toyota Australia www.ats-global.com

9. ATS Inspect Achievements
Toyota after using ATS Inspect for 1 ½
years:
Reduced the number of average defects
per month from ± 20.000 to ± 5.000, and
continue to improve.
Removed all paper in the Quality Control
Division
Reduces number of resources involved
with quality data gathering and reporting
(retrained and moved in organisation)
Real time feedback on issues
02/11/2009
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Case Study - ATS Inspect - Toyota Australia www.ats-global.com

10. 2009 Manufacturer of the Year Award
Despite tough economic times, this year’s Endeavour Awards
demonstrated Australian manufacturers are up to the
challenge. Katherine Crichton reports from the gala Award’s
ceremony in Melbourne.
“The world is going through some very tough times right now –
and when times are tough, it is the manufacturing sector we
look to for new ideas and new hope."
This was the message Industry Minister Senator Kim Carr
delivered at the sixth annual Endeavour Awards gala dinner
ceremony held in Melbourne last night which saw Toyota
Australia take out the prestigious 2009 Manufacturer of the
Year Award.
02/11/2009
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Case Study - ATS Inspect - Toyota Australia www.ats-global.com