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> Making Ever-better Cars > Initiatives to Achieve Carbon Neutrality
Software and Connected Initiatives > Commercial Sector Initiatives > Woven City
Karakuri for Non-powered Devices
We wonder if some of our readers have heard of
chahakobi dolls, tea-serving dolls manufactured in
the Edo period. Such mechanical dolls, designed
to carry cups of tea to guests and collect empty
cups, perform combinations of simple fundamental
movements (karakuri) and can be considered
a precursor to robots. The Japanese term karakuri
generally refers to non-powered mechanical
automata operating through a combination of
gears and shafts. They can therefore be deemed
the ultimate carbon-neutral devices.
At Toyota's Honsha Plant, we maintain a pro-
duction line called the TPS basic line. This facility
was built upon our predecessors' wisdom as well
as our ingenuity. In fact, going back to the con-
cept of karakuri, we have created an automated
line that does not use sensors or control devices.
The use of karakuri is intended to nurture
human sensibilities and inform our development of
equipment. For example, because at each stage a
karakuri mechanism must work properly for the
next action to occur, such mechanisms make it
Toyota's Honsha Plant
TPS Basic Line
Karakuri mechanisms must properly work at
each stage for the next action to occur
easy to detect problems without relying on sensors.
At Toyota, we replace pallets containing produc-
tion parts via non-powered operation, using this
mechanism in combination with automated
conveyance carts to achieve an unmanned process.
Collaboratively Employing the Latest
Technologies and the TPS
Toyota's efforts to create a "green factory" are
being promoted by collaboratively employing the
latest technologies and the TPS.
The first technology is automated conveyance.
At Toyota, transporting, itself, is considered
wasteful. The starting point is trying to not
transport at all. But, as that can often not be
done, if something needs to be transported from
point A to point B, we revise facility layouts to
shorten the distance between the two locations
while reducing the bulk of cargo and number of
items per load. We then develop an automated
conveyance system covering only the remaining
distance and carrying lightest possible loads.
In Woven City, a similar concept is utilized, in
which above ground and underground roads are
developed separately, with the latter used only by
fully automated logistics vehicles for the purpose
of goods distribution.
The second technology is automated inspection
using Al. There are many examples in the world of
automated inspection of defective products using
machine learning to reduce the need for human
labor. However, our goal is to use the vast amount
of data we are collecting from this process to
make essential improvements that will prevent
defects from occurring in the first place.
The third technology has to do with digital
transformation (DX) and loT. With regard to loT,
a technology that connects nearly everything to
the internet, we have experienced setbacks
despite our best efforts to become a forerunner in
the rush toward loT. Although we raised the
equipment utilization rate on production lines to
98% by pursuing continuous improvement and
applying the TPS, there remains the problem of
how to address the last 2%. It is a real problem
that can only be solved by the power of people.
Collaboratively Employing the Latest Technologies and the TPS
Karakuri
(vacuum replacement mechanism)
Toyota believes that people should not be turned
into machine-keepers. To get that final 2%, we aim
to simplify equipment and create equipment that
does not break down.
By combining this unique, human-centered,
Toyota thinking with DX and lot, we hope to
create the next generation of advanced
production lines.
In 2019, we launched a vehicle production line
that collaboratively employs the latest technologies
and the TPS in Mexico (see the diagram below).
Taking Full Advantage of the Power of Monozukuri
(manufacturing) Unparalleled by Global Peers
In the face of a forthcoming wave of new chal-
lenges, such as calls for carbon neutrality and the
need for DX, we at Toyota stand with our fellow
manufacturers around the world. Working hand in
hand with them, we will take on these challenges
and become the best automaker in town in each
region in which we operate.
Innovative equipment
Innovative equipment
Innovative equipment
Innovative equipment
Example: Oil seal press-fitting machine that
operates on karakuri principles
Making it easy to detect problems without
relying on sensors
Toyota
Conveyance cart >> Flowing rack
Karakuri (parts conveyor)
Motor
Kyushu,
Inc.
Conveyance cart Supply line
(new Ton Ton)
Karakuri
(automated fitting mechanism)
Karakuri (failproof system)
Main conveyor (SS turn)
SS subline conveyor
SS engine and rear
suspension installer
SS parts installation
Karakuri (parts conveyance)
assistance device
Bolt Lock
Multi-axis temporary fitting tool
Karakuri (conveyance carts)
Karakuri (parts conveyor)
Karakuri (parts conveyance)
Karakuri (parts conveyor)
Karakuri (ergonomic
operator support system)
Toyota
Auto
Toyota
Motor East
Body
Co., Ltd.,
Japan,
Aisin
Seiki
Co., Ltd.
Inc.
String-driven karakuri
conveyance system
Dream Carry
Gate-type conveyance system
Raku raku sheet
TOYOTA MOTOR CORPORATION
25
INTEGRATED REPORT
Empty-box returner
Karakuri
(fixed-volume material loader)
Subereon
Karakuri (wagon carts)
Placing parts fitting tools
closer to operatorsView entire presentation