"Foundation of the Automobile"
Stamping utilizes around forty-eight dies that produces approximately sixty-two parts for the Toyota Corolla. Stamping specializes in the blanking, forming, and inspection of steel coil rolls and high tensile strength material. When steel coils arrive at our facility, team members unload the material and cut it at the blanking process. Large overhead cranes move fifteen metric ton dies into position at the main Stamping process. Workers then load blanked material from the shelves and start the equipment. Robots move panels into stations where they are molded into the proper shapes and positioned to the end of the line for inspection. Team members inspect panels using diagrams of critical locations that must be confirmed. After a visual check is completed, panels are stacked and loaded into containers and then taken to weld processes.
Zone 3 Weld department produces around fifty-nine different components with approximately ninety-three robots. The majority of the processes are spot welding. In addition to utilizing robots our team members assist in every process. We have some critical processes geared toward the safety of the final part or product. Our team members in Zone 3 are trained to identify spot weld, material, and alignment defects. Our team members also sometimes use hammers, chisels, wire brushes, and studs in completing their processes.
ZONE 3 WELD
"Reliable Suspension Maker"
The Unit Weld department has mainly robotic arc processes. We produce the front and rear suspension, cowl, and front and rear lower arm. We utilize stamped parts, vendor parts, nuts, collars, and studs in order to complete processes with the help robots. The unit assembly department installs sub-components to them. Assembly team members use sealer, paint, drills, and two different bushing presses while running their processes. In this department team members are trained to identify arc weld, spot weld, and paint defects on parts that are produced.
"Face of the Automobile"
Plastics and Paint Department or RTA (Resin, Top Coat, and Assembly) consists of Injection, Paint and Assembly processes.
Injection process produces Instrument Panels (IP) substrates and front and rear bumpers by using an 1.8k ton and 2.6k ton injection press. We then send the IP to our onsite location at TMMMS. OSS (Onsite Supplier) receives these substrates and apply the Mono foam and the skin.
The Bumpers are sent to Paint Shop where primer, base and clear is applied, by using ten different robots. We have many color options for the Toyota Corolla. After Paint is applied, the bumpers are inspected for paint quality.
The bumper assembly process assembles the front and rear bumper using sixty-six sub-components. Our team members also install the safety and design components by using an impact driver.
PAINT & PLASTICS
"Physical Material Movement"
The logistics department is responsible for delivering parts to unit weld/assembly, zone 3 weld, and bumpers for daily production. Specifically, we load and unload an average of sixty one trucks of plastic and steel parts each day. We stage an average of 4,165 containers for shipping, and receive an average of 6,686 inbound containers daily. To operate safely, logistics team members are trained and certified to drive forklifts and tuggers.
"Inspector of Product Quality"
Quality Control (QC) Department inspects and evaluates our welding parts and assembled bumpers to ensure 100% good quality to our customer. Our team members go through training in order to be able to judge welds and plastic parts properly and use tools to evaluate parts on a check fixture. We use several different types of equipment such as wave scan, x-rite, water immersion tank, and the microscope. In addition to that, we have implemented a new technology that checks spot welds known as C-Scan. We also evaluate dimensional accuracy for bumper, welding, and the stamping shop.
"Technicians of Machinery"
The maintenance department is in charge of securing and maintaining all equipment that is used in the stamping, welding, resin molding, and resin paint processes at APMM. Our role is to work on daily preventative maintenance in order to keep our equipment in good condition. We constantly strive to extend longevity of machine parts, and improve our skills to reduce machine down time.
The die and mold maintenance department is in charge of tooling necessary to make stamped parts, bumpers and the instrument panel. We complete repairs and do preventative maintenance on all tools to keep the quality at a high level. Our team members utilize their troubleshooting skills to identify the root cause of problems and make countermeasures against re-occurrence.
"Innovators of Production"
The production engineering department is responsible for setting process standards for all processes (stamping, welding, injection and paint). Our mission is to establish, maintain and ensure process control, by using various tools and management methods. Our approach is based on a known cycle time, one-piece flow of manufacturing processes, and standardized work. Daily work for the engineers consists of support and analysis for unstable or down processes. We perform process control checks using auto grid analysis, and vectron analysis; comparing it to manufacturing quality control standards, and to master parts, key process controls, and boundary samples.
"Gateway to Learning"
The Safety department is responsible for the safety and health of all team members, customer, vendors and visitor that are on our property. Our mission is to establish and maintain a safety culture for everyone associated with APMM. This is done by setting rules, training the rules, auditing the activities and giving feedback both positive and negative.
Dojo is the starting place for all new team members. They are trained on the fundamental elements as well as Safety, Toyota Production Systems, KY (Kiken-Yochi = Hazard Anticipation/Prediction), Critical Eye, and 5S.
Our Kaizen department has the role of supporting production by designing, creating and making products that support production groups such as metal fabrication, process repairs and process improvements. They also have responsibility for daily preventative maintenance on equipment such as dollies and carts.
"Administrators of Purchasing, Manpower, and Money"
Our administrative departments include Accounting, Human Resources, Information Technology, and Purchasing/Sales departments. Although the primary tasks are office duties, the administration team members also learn the production side of business to understand our company goals and our team members’ needs.