Toyota Challenge – LEAN Manufacturing and Production Methods

Toyota has recently visited The JCB Academy to start the Toyota Challenge, a series of engineering based challenges which include building an engine in a limited amount of time, producing a fuel rail spacer on lathes, designing and building a wind-powered car, and LEAN manufacturing and production exercises.

The team from Toyota consisting of John Byrne, Principal Specialist – Technical Skills Development, and Mandy-Jayne Evans, Senior Specialist – Young People Education, delivered sessions to the Year 11 learners covering LEAN manufacturing and production methods used at Toyota. The sessions are to help learners reinforce their learning and provide further knowledge to implement into their coursework.

The Toyota team started with a presentation on LEAN manufacturing and production methods, giving learners an insight into a range of processes including efficiency, quality, production flow, material waste, and budget control.

The learners were put into groups of five, with one group being selected for the first experiment. The selected group of five learners were asked to assemble five dismantled Bic pens, which had been laid out on the table in front of them: clear plastic shaft/barrel, ink cartridge, and plastic cap. The other learners in the class watched the process and were then given a brief talk by the Toyota team, followed by a group discussion on how they could speed up the process. The group of five was then asked to assemble the pens, taking on board the suggestions made. The task teaches the learners how simple processes can make manufacturing production more efficient.

The learners were then asked to assemble a Lego excavator using all of the advice and techniques given by the Toyota team and gained through the group discussions. Sets of Lego are often used in the manufacturing industry to teach LEAN manufacturing and production methods, Toyota being one of those using this method.