PDF[622KB/13pages] - Toyota Industries Corporation

Toyota Industries Close-upToyota Industries Corporation (“Toyota Industries”) isdivided into four segments: Textile Machinery, Automobile,Materials Handling Equipment, and Others. These arefurther subdivided into a wide range of business/operationcategories. The following pages give details of our range ofbusiness fields and product groups, our 75 years of history,and our corporate organization. We hope that this will giveall of our stakeholders—including shareholders, investors,and customers—a deeper understanding of ToyotaIndustries.Passion and Progress in ManufacturingAs a manufacturing company, our vital function is to craft products.Ever since our foundation, we have channeled our passion for manufacturinginto our mission of bringing customers superior products at fair prices.We constantly seek to improve and update our manufacturing facilitiesso that we can make products of superb quality in the most efficient way.Henry Ford’s mass-production methods revolutionized automobile manufacturing andToyota Motor Corporation’s “lean manufacturing” method enabled another huge leap inproductivity. But just as important as these major revolutions are the many smallimprovements that add up to a large overall advance in productivity.We, Toyota Industries, are a group of people devoted to the continuous improvementof productivity and the manufacturing of products.While engineers and designers at Toyota Industries have developed new productsand improved existing ones, our factory employees have made just as important acontribution to better productivity through their proposals for improving work processesand equipment. We recently embarked on an ambitious project to shorten developmentprocesses and improve productivity by revolutionizing development and manufacturingmethods through the adaptation of IT.69TOYOTA INDUSTRIES CORPORATION ANNUAL REPORT 2001

Toyota Industries Close-upMaterials Handling EquipmentThe Materials Handling Equipment Segment consists of TOYOTA Material Handling Companyand BT Industries AB. TOYOTA Material Handling Company is divided intothe industrial vehicle business and the materials handling system business.TOYOTA Material Handling CompanyMoving into worldwide markets with industrial vehiclesand other advanced industrial equipment products70TOYOTA INDUSTRIES CORPORATION ANNUAL REPORT 2001Industrial Vehicle BusinessReaching for success through superiorR&D and customer satisfactionToyota Industries’ industrial vehicle business began in1956 with the introduction of the LA model 1-tonforklift truck. Since then, we have developed a varietyof superior industrial vehicles, such as electric towtractors with an AC (alternating current) drive systemand lift trucks boasting features such as Japan’s first 4-wheel drive, standard power steering, which had ahuge impact on the industry, and low-noise. ToyotaIndustries currently leads the world market with a fullline-up of internal combustion and electric forklifttrucks with capacities ranging from half a ton up toover 40 tons. In addition, we develop andmanufacture numerous other industrial vehicles,including skid steer loaders, shovel loaders, and towtractors for use at places such as airports.Our emphasis in making lift trucks has been, andalways will be, on making products that are safer andas easy as possible for the user to operate. In 1998,we introduced the GENEO series (called the 7-Seriesoutside Japan) of internal combustion,counterbalanced forklift trucks with capacities from1 to 5 tons, which boasted our world-first System ofActive Stability (SAS), a system for enhancing thestability of lift trucks. In 1999, we introduced theGENEO-B (called the 7FB outside Japan) electriccounterbalanced forklift trucks with capacities from1 to 3.5 tons. In addition to the highly rated SAS, theGENEO-B featured the AC control system as standardequipment.We aim to continue being the world’s leadingmanufacturer of industrial trucks as we continuouslydevelop state-of-the-art products in order to satisfycustomer needs worldwide.GENEO (7FD25)Internal Combustion CounterbalancedForklift Truck (1 to 5 ton)GENEO-B (7FB15)Electric CounterbalancedForklift Truck (1 to 3.5 ton)GENEO-RElectric Reach TruckTow Tractor (2TD20)Skid Steer Loader (4SDKL8)

Materials Handling System BusinessCreating materials handling systemsthat revolutionize the way goods areconveyed, stored, sorted and picked inwarehouses and factoriesIn today’s IT age, information travels instantaneouslyover networks around the world. This increasedspeed of information has necessitated greater speedand efficiency in the field of distribution. We offercustomers improved efficiency in their distributionwork by developing a variety of materials handlingsystems such as automatic guided vehicle systems andautomated storage/retrieval systems. Our wealth ofknow-how in materials handling, which has beenaccumulated and developed based on the ToyotaProduction System (hailed as one of the world’s mostsuccessful production control systems), helps usprovide customers with optimal materials handlingsolutions. Examples of the remarkable materialshandling systems equipment we’ve developed includethe Road Sorter H, our high-end automatic guidedvehicle system that is easy to maintain and has a smallturning circle, thanks to AC servo-motor controlledsteering wheels, and the Rack Sorter BP, a buildingtypewarehouse system that allows the storing of vastamounts of goods on shelves up to approximately 30meters high. We also develop and manufactureautomated storage/retrieval systems and automaticguided vehicle systems for clean rooms, which areindispensable for the production of electroniccomponents. We employ our original non-contactpower supply systems in our automatic guidedvehicle systems and automated storage/retrievalsystems for clean rooms. Because these systems useelectromagnetic force to supply electrical powerwithout physical contact to moving parts, theygenerate less dust and thus are ideally suited for usein dust-sensitive environments such as clean rooms.Note: Toyota Industries’ automatic guided vehicle systems, automatedstorage/retrieval systems and certain other materials handling systemsand products are generally sold only in Japan.Rack Sorter BPAutomated Storage and Retrieval System(Building Rack Type)71TOYOTA INDUSTRIES CORPORATION ANNUAL REPORT 2001Rack Sorter PAutomated Storage and RetrievalSystem (Pallet Type)Rack Sorter BAutomated Storage and RetrievalSystem (Plastic Container Type)Road Sorter H (ACBH10)Automatic Guided Vehicle SystemRack Sorter CleanAutomated Storageand Retrieval Systemfor Clean Rooms2AFBR15Automatic Guided Forklift TruckMobile Sorter B (MS05)Rail Guided Vehicle SystemMobile Sorter CleanRail Guided Vehicle Systemfor Clean Rooms

Toyota Industries Close-upMaterials Handling EquipmentBT Industries ABDeveloping warehouse trucks for the global market72TOYOTA INDUSTRIES CORPORATION ANNUAL REPORT 2001BT Industries AB (“BT Industries”) is the world’sleading supplier of warehouse trucks and has a strongglobal customer base, particularly in Europe and NorthAmerica. With its wide range of materials handlingknow-how, BT Industries helps customers improvematerials handling efficiency and lower costs. Detailedanalysis of customers’ sites allows BT Industries tooffer the best materials handling solution possible.Customers’ needs are reflected in the development ofBT products that offer high performance, lowmaintenance and maximum cost performance.BT Industries stays close to its customers throughdedicated sales networks. BT Industries offers a widerange of warehouse trucks, including hand pallettrucks, reach trucks, order picking trucks, very narrowaisle trucks and others. The company offerscounterbalanced lift trucks as well.BT LIFTER (Hand Pallet Truck)BT has manufactured more than 2 millionof these original hand pallet trucks to date.With a lift capacity of 2,300 kg, the BTLIFTER can be used wherever pallets needto be moved.BT MINIMOVER (Electric Pallet Truck)Launched in 2001, the MINIMOVER is a light and agileyet powerful aid for horizontal transporting. Itselegant style and ease of use make it perfect for use inplaces such as supermarkets.BT ORION (Electric Pallet Truck)The ORION series of electric pallet trucks isintended for heavy-duty horizontaltransporting. Combining large batteries,powerful motors and a driver platform withCAN technology, these pallet trucks offerhigh productivity and low maintenance.

REFLEX (Reach Truck)The REFLEX reach trucks are designed forintensive stacking and horizontal transporting.Ergonomics and performance have beencombined into a superbly productive line oftrucks.OPUS (Order Picking Truck)The extensive OPUS line of low-levelorder pickers is used for order picking ofa multitude of items, from auto spare partsto consumer goods. The model shownhere has extra-long forks for roll cages.OPUS (Order Picking Truck)The OPUS line also includes models with elevating platforms,allowing the operator to work comfortably at first and secondlevel shelves.COMBI (Very Narrow Aisle Truck)The COMBI line consists of high-lifting “man-up”machines for combined pallet handling and orderpicking. The trucks are engineered for intensiveuse—even around the clock—365 days a year.73TOYOTA INDUSTRIES CORPORATION ANNUAL REPORT 2001CARGO (Counterbalanced Truck)The CARGO line of counterbalanced trucks, comprisingelectric, diesel and gas-powered machines with liftcapacities up to 5 tons, completes the BT product line-up.OPAL (Order Picking Truck)The OPAL order pickers are designed for order picking at mediumheights, exceeding four meters. The model shown is equipped witha walk-through platform for handling of bulky goods.

Toyota Industries Close-upCompressor DivisionA world leader in the manufacture of compressors,the core part of a car air-conditioner74TOYOTA INDUSTRIES CORPORATION ANNUAL REPORT 2001Car air-conditioners use the heat of evaporation ofrefrigerants to cool the inside of cars. The heart of acar air-conditioner is the compressor. ToyotaIndustries has been a leading manufacturer of car airconditioningcompressors with outstanding, unrivaledtechnologies such as compressors for electric vehiclesand an external signal-controlled compressor withone-way swash plate continuous variabledisplacement, which automatically adjusts itsdisplacement according to the cabin temperature andCar Air-Conditioning SystemCompressorCompresses the refrigerant gas,vaporized in the evaporator, sothat it can be easily liquified.Heat-sensingcylinderRefrigerant (gas)Outside airHigh-temperature,high-pressure gasCool airEvaporatorVaporizes refrigerant gas and removesheat from warm air supplied by a fan tothe passenger compartment as itpasses through the evaporator, therebycooling the passenger compartment.Blower motorInterior airWarm airEngine cooling fanCondenserCools and liquifies the high-temperature,high-pressure refrigerant gas sent fromthe compressor.the load on the engine, resulting in lower fuelconsumption. We have a large market share, both inJapan and around the world, supplying carmanufacturers with state-of-the-art, compact andlightweight products, way ahead of the competition.The compressor is an important element inensuring a comfortable drive. It’s also important indetermining the impact a car has on the environment.As part of our long-standing commitment to theenvironment, we develop compact, variableExpansion ValveInjects the high-temperature, high-pressureliquified refrigerant through a small hole,causing the refrigerant to expand rapidly and itstemperature and pressure to drop.LiquidtankRefrigerant (liquid)Fixed Displacement TypeContinuous Variable Displacement Type10S17 Compressor(Fixed Displacement,Swash Plate Type)7SBU16 Compressor(Variable Displacement,Swash Plate Type)6SEU12 Compressor(External Signal-Controlled, VariableDisplacement, Clutchless Type)

displacement compressors that contribute to fuelefficiency by placing minimum burden on the carengine and next-generation compressors that use newrefrigerants such as carbon dioxide (CO2) as a substitutefor CFCs.Toyota Industries develops and manufactures varioustypes of car air-conditioning compressors, our main typebeing the swash plate type. There are two types ofswash plate compressors: a fixed displacement typewith the swash plate angle fixed to keep the volume ofthe refrigerant compression chamber and the coolingcapacity at a constant level; and a variable displacementtype (one-way swash plate type) with the swash plateangle controlled automatically to change the volume ofFixed Displacement TypeSwash platePiston•Swash plate angle fixed• Compression chamber volume andcooling capacity fixedContinuous Variable Displacement Type(Maximum Displacement)the refrigerant compression chamber and control thecooling capacity. Automatic displacement control canbe achieved with two methods: an internallycontrolled variable displacement method thatresponds to the heat load of the compressor, therebymechanically controlling the displacement; and anexternal signal-controlled variable displacementmethod, which uses sensors that detect various factorssuch as interior and exterior temperatures andhumidity levels, enabling the magnetic valve toregulate the displacement of the compressoraccordingly, thus contributing to higher fuel-efficiencyand enhanced driving feel.Swash platePiston•Variable swash plate angle•Changes the swash plate angle to controldisplacement, thereby altering cooling capacity(Minimum Displacement)75TOYOTA INDUSTRIES CORPORATION ANNUAL REPORT 2001Features: Excellent overall performance—compact and lightweight withsimple structure, high reliability,high energy efficiency, and lownoise and vibrationFeatures: High fuel efficiency, smooth switchingon and off, temperature at cool airblower fixedSCS06 Compressor(Scroll Type)SV07 Compressor(Vane Type)ES25 Electric Compressor(Hermetic Scroll Type)Viscous Type Power Heater(Vehicle Cabin SupplementaryHeater)

Toyota Industries Close-upVehicle DivisionContributing to the Toyota Group by assemblinghigh quality, environmentally friendly compact cars76Today, safety and environmental concerns areimportant elements in developing cars. We currentlymanufacture the Vitz (Yaris in Europe), the productionof which commenced in 1999, succeeding the Starlet.Having the lowest level of fuel consumption in itsclass, the Vitz (Yaris) is a strategic small car for ToyotaMotor Corporation (“TMC”) worldwide. In addition tobeing environmentally friendly, it’s also equipped withadvances in safety technology such as EBD (electronicbrake distribution), ABS (antilock braking system) anddual SRS airbags.We also manufacture the Sprinter Carib (called theCorolla Wagon outside Japan) for TMC, and startedproduction of TOYOTA’s compact SUV RAV4 in May2001 and the bB Open Deck, a new compact car, inJune 2001.TOYOTA INDUSTRIES CORPORATION ANNUAL REPORT 2001Vitz (Yaris in Europe)RAV4Sprinter Carib(Corolla Wagon Outside Japan)bB Open Deck(Available Only in Japan)

Toyota Industries Close-upToyota at WorkEngine DivisionManufacturing a line-up of engines for small cars andlarge sport utility vehicles (SUVs)Environmental concern in recent years has created ademand for environmentally friendly engines. ToyotaIndustries is striving to develop and manufacture, incollaboration with TMC, engines that offer power yetfuel efficiency and high output yet low noise.We manufacture diesel and gasoline engines inclasses ranging from 1.5 liters to 4.7 liters. Theengines we produce are used in TOYOTA-brandautomobiles and forklift trucks. We are going all out inour joint efforts with TMC to develop environmentallyfriendly engines that offer power, quietness, and lowvibration in a compact package.Our flexible manufacturing system uses automaticguided vehicle systems to efficiently assembleapproximately 200 engine parts, thus replacingconveyor belts.77Diesel Engines1CD Diesel Engine(Displacement: 2.0 Liters,Used in the Avensis and Corolla)1HZ Diesel Engine(Displacement: 4.2 Liters,Used in the Land Cruiser and Coaster)3C-E Diesel Engine(Displacement: 2.2 Liters,Used in the Corolla)TOYOTA INDUSTRIES CORPORATION ANNUAL REPORT 2001Gasoline Engines2UZ Gasoline Engine(Displacement: 4.7 Liters,Used in the Lexus LX470)1FZ-FE Gasoline Engine(Displacement: 4.5 Liters,Used in the Land Cruiser)4Y Gasoline Engine(Displacement: 2.2 Liters,Used in Industrial Vehicles)

Toyota Industries Close-upToyota at WorkElectronicsThe key to the future growth of the companyOur Electronics business consists of three separate operations:the Technology Development Center, ST Liquid Crystal Display Corp., and TIBC Corporation.Technology Development CenterTaking cars into a new age of electronic controlthrough the development of electronics equipment and devices78TOYOTA INDUSTRIES CORPORATION ANNUAL REPORT 2001Our Technology Development Center conductsresearch and development in various fields. In July2001, we integrated the center with ourSemiconductor & Electronics Equipment Division andbegan aggressively developing and manufacturingelectronic components for automobiles. TheTechnology Development Center manufactures mainlypower supply- and communications-related products.In the field of car electronics, we develop andmanufacture a variety of products, including DC-ACinverters (pre-installed type and portable type), whichconvert the DC 12V current from an auxiliary batteryto AC 100V so that home electrical appliances (8V)can be used in the vehicle in Japan; inductive batterycharging systems for electric vehicles; and DC-DCconverters used in hybrid cars. We also manufacturesemiconductors, SS wireless modems and the ACcontrollers built into the GENEO-B (called the 7FBoutside Japan) electric counterbalanced forklift trucks.Battery Charging System for EVPower MOSFET ModuleDC-DC Converter for the PriusDC-AC Inverter (Pre-Installed Type)

ST Liquid Crystal Display Corp.The growing nucleus of Toyota Industries’electronics business holds high-tech promiseST Liquid Crystal Display Corp. (“ST-LCD”), establishedas a joint venture with Sony Corporation, manufactureslow-temperature polysilicon TFT LCDs, a nextgenerationdisplay panel.In addition to having a high aperture rate andconsuming little power, low-temperature polysiliconTFT LCDs make possible miniaturization of the displayunit because the display device and its driver circuitscan be integrated onto the same TFT glass substrate.These compact, cost-reducing display panels thus holdpromise for applications such as digital video and stillcameras, as well as in-car monitors. With thesecharacteristics predicted to create a huge demand forlow-temperature polysilicon TFT LCDs, ST-LCD standsto play an important role in Toyota Industries’electronics business.TIBC CorporationLow-TemperaturePolysilicon TFT LCDsManufacturing plastic package substrates for IC chipsetshelps make electronics products smaller and lighter79TOYOTA INDUSTRIES CORPORATION ANNUAL REPORT 2001TIBC Corporation (“TIBC”), a joint enterprise ofToyota Industries and Ibiden Co., Ltd. (“Ibiden”),entered the market for electronic substrates, whichare used for IC modules that are vital for a range ofproducts including PCs, digital video and stillcameras, mobile phones and memory boards. TIBCmainly manufactures ball grid array (BGA)-typeplastic package substrates, which allow ICs to offermaximum functionality with minimum size andweight, and flexible printed circuit (FPC)-typesubstrates for IC cards. These products are soldthrough Ibiden to chip manufacturers and otherhigh-tech companies worldwide.Ball Grid Array (BGA)-TypePlastic Package Substratesfor IC ChipsetsFlexible Printed Circuit (FPC)-TypeSubstrates for IC Cards

Toyota Industries Close-upToyota at WorkTextile Machinery DivisionContributing to innovation in the global textile industry80TOYOTA INDUSTRIES CORPORATION ANNUAL REPORT 2001The roots of the Toyota Group go back to the renownedJapanese inventor Sakichi Toyoda and his invention ofthe automatic loom. Since then, the company hasdeveloped and manufactured textile machinery, themajority of which has been supplied to customersoutside Japan. Toyota Industries manufactures two maincategories of textile machinery: spinning machinery forspinning cotton fibers into yarn; and weavingmachinery, on which yarn is woven into fabric in thedirections of weft and warp. To keep up with theadvancing needs of the market, we continuouslyincorporate the latest technological developments,including control technology, mechatronics and IT, intoour textile machinery.Our Textile Machinery Division’s flagship product,the JAT610 air-jet loom, has garnered the number-oneWeaving Machineryshare of the world market thanks to the high level ofpraise received from our customers. After taking overthe water-jet loom business from Nissan Texsys Co.,Ltd., we applied the proprietary electronics technologydeveloped for our air-jet weaving machines andintroduced the LW600 series water-jet loom in 1999.We also sell preparatory machinery for weaving, suchas sizing machines.Customers around the world also know and trustus as one of the leading manufacturers of ring spinningframes and roving frames.The Textile Machinery Division aims to offer theworld’s leading brand by continuously developingproducts that meet customers’ needs, therebymaximizing customer satisfaction.JAT610 Air-Jet LoomLW600 Series Water-Jet LoomMackee EagleSizing Machine for Spun YarnSpinning MachineryRX240 Ring Spinning FrameFL100 Roving FrameDX7A Drawing Frame

Toyota Industries Close-upSub-DivisionsMachinery & Tools Sub-DivisionExcelling in press die manufacturing technologyThe Machinery & Tools Sub-Division isinvolved in the design and manufacture ofautomobile press dies, mainly for TMC.These press dies are highly rated for theirhigh quality and precision by automobilemakers both in and outside of Japan. With itscapability to produce higher quality pressdies at a lower cost and achieve quickdelivery times, the Machinery & Tools Sub-Division is helping automobile makersmanufacture better cars.The Mechatronics Engineering Sub-Division iscommitted to promoting in-housemanufacturing of key machining andassembling equipment. This includesmanufacturing equipment for the CompressorDivision and Engine Division as well as for STLiquid Crystal Display Corp., whichmanufactures next-generation LCDs. TheMechatronics Engineering Sub-Division alsodesigns and manufactures advancedmanufacturing equipment to help improveproduction efficiency and labor savings in thecompany and its group companies, thusboosting Toyota Industries’ competitiveness.Mechatronics Engineering Sub-DivisionThe Machinery & Tools Sub-Division manufactures varioustypes of automobile press dies anddistributes them to ToyotaIndustries’ Vehicle Division andautomobile makers such as TMC.Contributing to the improvement of process technologythrough the design and production of manufacturing equipmentfor intracompany business divisions81TOYOTA INDUSTRIES CORPORATION ANNUAL REPORT 2001Equipment developed and manufactured by the MechatronicsEngineering Sub-Division is utilized in Toyota Industries’ compressorbusiness and by ST-LCD, enhancing the productivity and competitivenessof these operations.