Together with Customers
The Toyota Boshoku group has an integrated system of design, manufacturing and sales and is committed to production that prioritises safety and quality in order to provide high-quality, high value-added and attractive products from the customer’s perspective and standpoint, thereby inspiring and exciting customers.
Promoting education, training and awareness-raising activities for quality
In order to ensure the safety and quality of our products, the Toyota Boshoku group has confirmed the fundamentals of quality assurance in the three areas shown below and is promoting education, training and awareness-raising activities related to quality.
- Devise technical drawings that factor in quality
- Create a process that guarantees the quality of drawings
- Enhance quality in daily manufacturing operations
The Toyota Boshoku group conducts systematic education, training and awareness-raising activities that can be shared and built into the three domains of design, production engineering and quality in order to ensure product quality and is also developing professional human resources with regard to quality at an adequate global level.
In fiscal 2015, we formulated a human resources development plan based on a skills map that establishes the capabilities necessary to be a supervisor related to quality, candidate for dispatch to regions outside Japan and a future team leader in the workplace.
Enhance and strengthen quality assurance system
On the basis of securing the safety of customers and delivering products that inspire, we are striving to enhance the quality assurance system for the Toyota Boshoku group on the back of integrated efforts by the Quality Assurance Division, Global Quality General Control Department and TQM Promotion Department in the quality field.
Reinforcing our global quality assurance system
The Toyota Boshoku group, including group companies around the world, is working to strengthen our quality assurance system.
At quality function meetings, global policy related to quality management is formulated and key issues are discussed and followed up on while determining the quality policy of each region and its implementation status. Information is shared at the global level to enable effective quality-related measures. The Company is cooperating with each region to ascertain the status of quality within regions and deploying initiatives toward achieving targets. In fiscal 2015, audits were performed in each region for key processes in an effort to make improvements while courses were given with the aim of nurturing members able to audit these key processes.
Establishment of product auditing system
In addition to safety assessments of individual automotive parts, it is also necessary to respond to certification systems related to safety in completed automobiles. The Toyota Boshoku group is maintaining China Compulsory Certification, a safety standard for products imported to China, and going forward, we will formulate an auditing plan for important features in relevant legislation in respective countries and regions and conduct auditing as required.
Expansion of ISO/TS 16949 certification
The Toyota Boshoku group promotes acquisition of ISO/TS 16949 certification to manage and maintain quality assurance systems. ISO/TS 16949 is the international standard related to a quality management system that provides for defect prevention and the reduction of variation and waste in the automotive supply chain.
In fiscal 2015, six plants at entities outside Japan were newly certified, making a total of 69 plants with the certification
Deployment of quality-related activities
The Toyota Boshoku group deploys quality-related activities to realise safety and comfort for customers who drive cars as well as automakers.
Prevention of significant quality issues
The Toyota Boshoku group is implementing 5N activities globally for all parts earmarked for commercialisation and is working to further advance skills in order to prevent major quality deficiencies and claims.
5N activities, one of the most important initiatives with regard to preventing quality issues, identify areas that are either new or have been modified in the design of a new product or process from five perspectives: structure, materials, manufacturing method, processing and application. This approach helps to thoroughly eliminate any deficiencies in advance. For instance, if a totally new material is slated for use, it is set and registered as a product subject to 5N activities. Development, production engineering, procurement and quality divisions then work together to prevent deficiencies in key areas of quality through evaluation and verification activities. The implementation status of 5N activities is evaluated at a production transfer meeting held at each stage. Products for which these activities have not been completed do not make it to market.
Design and process development to prevent defects in products
The Toyota Boshoku group is undertaking efforts on a daily basis in design and process development to prevent defects both inside the organisation and at suppliers. In fiscal 2015, we set up a model line toward the establishment of a work manual so that anyone can produce good quality products and conducted inspection of the manual and compliance with its provisions as we continue to promote activities that serve to raise quality.
Swift discovery and response to defects in products in the market
Toyota Boshoku promotes activities aimed at swift discovery and response to serious defects in products in the global market. Defects with a high propensity to cause harm, which occur frequently or may impact the market, are classified by level of importance and registered. Countermeasures are then implemented in line with a set deadline based on comprehensive follow-up procedures. Clear rules are defined for defects designated with a high ranking, including countermeasures, the deadline for implementation and method of implementation, thereby enabling a swift response. In fiscal 2016, we will continue making an analytical system for defective parts in the frame that have been newly added to Toyota Boshoku parts in line with consolidation of the seat frame component business.
Promotion of QC Circle/SQC activities
As part of Total Quality Management (TQM) activities, the Toyota Boshoku group conducts Quality Control (QC) Circle activities for members with technical skills and Statistical Quality Control (SQC) activities for members with administrative and engineering skills.
As for QC Circle activities, in addition to tier-based training for leaders, advisors and supervisors, the QC Circle Promotion and Operational Case Study presentation is held in Japan as an occasion for presenting activity results. The All Toyota Boshoku QC Circle presentation is also held annually to present global activities, in which circles that have won in preliminary competitions in respective regions worldwide including Japan participate and make presentations. As an example of interchange with a country outside Japan, in the preliminary competitions in the Asia & Oceania region, the TQM Promotion Department took the lead in providing guidance on how to prepare materials and offering advice on all of the cases presented, which served to further enhance the level of results.
In SQC activities, training is conducted according to introductory-level, intermediatelevel and advanced-level job classifications and is used to help resolve issues and problems. This promotes the sharing of activity results via presentations and serves to advance knowledge and technologies related to quality. As a means to determine the results of these activities and assess individual capabilities, we urge members engaged in quality-related fields to undergo the QM/QC Examination so we can continuously foster professional human resources in this area.
In order to protect the rights of customers using our products, the Toyota Boshoku group cooperates with automakers to quickly respond when receiving claims for automobile components, thereby ensuring repair, replacement and other appropriate service. As for products besides car components, we are responding to various customer needs as well.