Toyota

Paint Shop Process

Reducing the environmental impact of our UK operations has been a consistent activity since our first vehicle left the line. With a challenging spirit TMUK has continuously applied the Toyota Production System (TPS) and kaizen (the Japanese word for “continuous improvement”) in our four main areas of focus; water use, energy use, VOC emissions and waste produced.  As the graphs clearly show we have enjoyed considerable success but we believe we can do better!!

Striving towards the ultimate Eco Factory, TMUK continues to maximise the benefit of existing activities but is also actively developing new initiatives and is engaged with practical pilot projects of new technology on site, such as THERM.

THERM offers us an opportunity to identify potential energy “matches” between processes and buildings which it is currently difficult to complete using existing methods. The chance to participate in such a project with another sector, academia and a software supplier is unique and already has provided many benefits. Our aim is that through THERM’s leadership we can contribute to society in a positive way.

The Toyota Paint Shop Process paints the car in its final colour by sending the white body (after welding) through different energy intensive sub processes.  The key sub processes use a mix of primary, secondary and tertiary types of energy, which we are targeting with this pilot project to investigate how waste from one area can be effectively harnessed as inputs to other areas.

Within a typical vehicle production plant the Paint Shop Process uses 57% of total energy, with the majority (95%) linked to Steam, Electricity and Gas use.  When you break the energy use down further; 57% of Electricity is consumed by the Painting Booths, 82% of Gas by the ovens, and 89% of Steam by the Painting Booths.

Partners

Toyota Integrated Environmental Solutions Cranfield University De Montford University Airbus Technology Strategy Board

Pilot Projects