tot workshop -- case study – developing a tot solution for toyota ms sarah drew, burton college
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World Class Train the Trainer Projects
Toyota Case StudySarah Drew
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The College
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BrandsToyota UK, JCB, Rolls Royce, Johnson Controls, Unilever
and The Football Association
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Toyota - In the World • Toyota continued skills investment through the recession, despite
unfavourable economic conditions. • One of the world’s leading automotive manufacturers• Operates 75 manufacturing companies across 28 countries globally• Markets vehicles in more than 170 countries
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Deeside, North Walesengine manufacturing
Toyota Manufacturing UK Overview
• Start of production Sept 1992 • 484 employees• £700 million investment
Burnaston, Derbyshirevehicle manufacturing
• Start of production Dec 1992 • 2,786 employees• £1.15 billion investment
•Largest and most experienced plants in Europe•Toyota and BSDC - successful 10 year partnership•Youth Apprentices, 3000 adult workers
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Core philosophies
CHALLENGE
KAIZEN
GENCHI GENBUTSU
CONTINUOUSIMPROVEMENT
TEAMWORK
RESPECTRESPECTFOR
PEOPLE
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Train the Trainers
College Toyota
Sustainable Workforce
Introduce new technology
3,000 Employees
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Working together
Role
Facilitated funding agreement
Supported with mapping activity – continuing to do so
Advice on developing higher level apprenticeship scheme
Role
Brought efficiencies into the qualification process
Motivated members to consider further education
Role
Intermediary between TMUK and awarding bodies
Provided master trainers
Trained TMUK members to become trainers
Managed quality & verification process
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Working together
• Aligned existing Toyota training to national qualifications – standardisation across plants
• Train and develop Toyota staff to become trainers• Bring different skills to the partnership to ensure both
sides develop and learn• BSDC trained Toyota trainers; Toyota trained college
trainers; working together; mutual strengths• Classroom based theory plus training in company on
the shop floor – business improvement projects• Together, the training team delivered 10000+
qualifications• Collaborated on new diploma for hybrid engineering
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Benefits from the training intervention •Company performance improved in terms of quality, cost and delivery •Highly motivated work force •College capability increased in advanced manufacturing •College developed lean process for delivering education •New technology introduced into the UK
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Turning the corner
• Introduced Auris Hybrid Synergy Drive • supported by unique qualification
• Returned to lean, efficient manufacturing • (full time working and lean manning)
• Number of employee ideas (bottom up) has increased
• Cost reductions have placed them in a stronger position
• Significant quality improvement activitiesContributions from skilled, educated workforce=
stronger company
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