The Future of Collision Repair On Time System - Locate Your OEM ...

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Dedicated to promoting quality collision repair of Toyota ve h i c l e s
Parts and Repair Organization Support
The Toyota
On Time System
The body shop
of to m o r row is
h e re to d ay —
New technologies,
better safety
equipment
and improved
production systems
The Future of
Collision Repair

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C o n t e n t s Vol. 4 Issue 9
3 Sowing the Seeds—
and Setting the
Standards: The National
Automotive Technicians
Education Foundation
Quality starts in the
classroom. The National
Automotive Technicians
Education Foundation
(NATEF) is setting the
standards that are shaping
the quality of your
future technicians.
4 The Toyota Production
System—How it Evolved,
What it Means to
Body Shops
Created to streamline the
automobile production
line, the principles of the
Toyota Production System
help enable body shops to
eliminate waste, raise
efficiency and increase
quality in today’s competitive
environment.
6 Toyota Supporting the
Industry—From Parts to
Performance
Toyota support for body
shops across the country
ranges from parts, technical
training and certification,
to the On Time
Collision Repair System
and nurturing careers in
collision repair.
8 On Time Collision
Repair—A Glimpse
at the Future
On Time Collision Repair
is quickly revolutionizing
the role of the collision
repair facility.
10 Pros Tips: Cladding Colors
Are you ready to paint a
two-tone vehicle? This
article provides color
codes and describes
where to find more
information.
Collision Pro s
Editor: Doug Stein Managing Editor: Karl Krug Copywriting and Design: Liehr Communications Refer all correspondence to: Collision Pros,
Toyota Motor Sales, U. S. A., Inc., 190 01 S. Western Ave., H 211, Tor ranc e, Califor nia 905 0 9. Fax (310) 974 - 5908 E-mail: collisionpros @ toyota. com.
Collision Pros is published four times a year by Toyota Customer Servic es, Pro duct Management De par tment. Contents may be re printed with
p er mis sion. © 20 01 Collision Pros. M DC# 00117- 0 0 6 01- JUL 01

*CP13 2/23/05 11:02 AM Page 3
TPS continued from page 5
fluctuations in demand.
• Quality assurance that each
process will supply only good
units to the next process.
• Respect for humanity that’s
constantly nurt u red—a necessity
because the system is depen-
dent upon human re s o u rces to
attain its cost objectives.
TPS in the Body Shop
There are numerous ways these principles
translate to the body shop. Fo r
example, the Toyota On Time Collision
Repair System (OTCR) is a way to
i n c rease shop productivity without
expanding or adding technicians. Based
on the principles of TPS, OTCR is
based on a logical step-by-step pro c e s s
that minimizes bottlenecks and
s t o p / s t a rt repair cycles. The result is
d e c reased cycle time, smoother workf
l ow of both large and small jobs,
and an increase in “d e l i ve red when
promised” rates.
By far, howe ve r, one of the easiest and
most common applications of TPS principles
is the use of OEM (original equipment
manufacturer) parts. The most
o bvious efficiency in using OEM parts is
what He n ry Fo rd re a l i zed in the early
1900s. Na m e l y, that standard i zed part s
kept the production line moving because
w o rkers didn’t have to stop to re d r i l l
holes or realign poorly fitting pieces.
To d a y, we also re c o g n i ze that using
OEM parts saves even more than the
extra time spent on parts installation.
T h a t’s because unnecessary installation
time translates into lost opportunities for
other re venue-generating work. Fo r
example, if your technician spends an
extra hour installing an aftermarket fende
r, yo u’re losing an hour of the shop’s
billable time even if yo u’re paying the
t e c h n i c i a n’s flat rate. Plus yo u’re generat-
ing fewer re venue dollars to spread acro s s
e m p l oyee benefits, so benefits eat up an
i n c reasing percent of re venue.
In addition to valuable opport u n i t y
cost savings that can translate into
higher body shop profit margins, using
Toyota Genuine Pa rts can also boost
In addition to valuable opportunity cost savings
that translate into higher body shop profit margins,
using Toyota Genuine Parts also boosts customer
satisfaction and retention for a number of reasons.
customer satisfaction and retention for
a number of reasons. Ready parts availa
b i l i t y, uniform alignment and less
time spent on repairs mean the cust
o m e r’s car is delive red sooner. T h e
appearance and structural integrity of
the customer’s vehicle should be maintained
as well.
From uniform parts that increase
efficiency and eliminate wasted time, to
s t reamlined production and built-in
flexibility to adapt to the rapidly changing
industry—the principles of the timeh
o n o red Toyota Production System hold
benefits for eve ry body shop. And especially
for their customers.
11

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p rovide training to meet the pro g r a m
goals and performance objective s .
8 . Fa c i l i t i e s . The physical facilities must
be adequate to permit achieve m e n t
of the program goals and perf o rmance
objective s .
9 . In s t ructional St a f f . The instru c t i o n a l
staff must have technical competency
and meet all state and local re q u i rements
for cert i f i c a t i o n .
10. C o o p e r a t i ve Agre e m e n t s . Written
policies and pro c e d u res should be
used for cooperative and appre n -
ticeship training pro g r a m s .
A vocational institution’s program may become
certified in any of the following are a s :
• Structural Analysis and
Damage Repair
• Non-Structural Analysis
and Damage Repair
• Mechanical and Electrical
Components
• Plastics and Adhesives
• Painting and Refinishing
What’s in It for You?
An important question to ask is what
this means to the collision repair industry.
First and foremost, ASE-certified schools
under the NATEF standards are training
students who are in line to become the
technicians of tomorrow. Some may gravi-
12
Sowing the Seeds
Setting the Standards
&
NATEF continued from page 3
tate to your collision center, and the
NATEF standards help to ensure that they
will learn using the latest equipment and
be trained to a high industry standard.
N ATEF also has a mechanism to allow
local shop owners and technicians to play a
major role in enhancing the quality of training
at the local level. Each ASE-cert i f i e d
school is re q u i red by NATEF standards to
host an advisory committee made up of
local industry professionals. This gro u p
helps mold class content and is instru m e n t a l
in providing program feedback.
Members of this committee prov i d e
c u r rent industry input. This grassro o t s
e f f o rt helps ensure that classes offer re a l -
world experience rather than offering a
p u rely theoretical curriculum. That way,
when students graduate, they are ready to
become contributing technicians at a local
collision facility. While on-the-job training
is still a necessity, NATEF is designed
to help establish strong standards, which
in turn help technicians produce while
they refine their skills.
By participating on an advisory committee,
shop owners and technicians alike
can help impact the future of the re p a i r
i n d u s t ry. Your invo l vement helps yo u
become part of the solution.
Who Sets the NATEF Standard s ?
To keep NATEF standards up-to-date,
at least eve ry three years NATEF gathers
between 25 and 30 industry professionals
to re v i ew and revise the standards. T h i s
e n s u res they are always up-to-date and
evolve as technology evolves. You may volunteer
to serve with the group that
reviews these standards.
Another way you can become involved
in NATEF is to volunteer for an
Evaluation Team when a local school is
seeking ASE certification. The school’s
first step in the certification process is to
perform a self-evaluation.
Once their self-evaluation package is
submitted, it is re v i ewed by NATEF to
e n s u re that it meets NATEF criteria.
Fo l l owing the re v i ew process, NAT E F
schedules an Evaluation Team visit, led by
an Evaluation Team Leader (ETL). ETLs
are educators certified by ASE and trained
by NAT E F. The Evaluation Team also
includes one school appointee from the
local industry and a third person, who is
selected by NATEF or the ETL—which is
where you could come in.
Initial certification typically re q u i re s
two consecutive days of on-site evaluation
while students are in class. The focus of
this evaluation is to ensure that all standa
rds are being met. Additional team
members and evaluation days may be
re q u i red to complete the on-site eva l u ation
if more than one program has been
submitted for certification.
What is CASE?
N ATEF is also invo l ved in Continuing
Au t o m o t i ve Se rvice Education (CASE).
CASE is a vo l u n t a ry ASE certification program
for training organizations that prov i d e
continuing education to working automotive
technicians. NATEF also sets these standard s
and administers the program while ASE certifies
these training providers. In fact,
Toyo t a’s entire Collision Repair & Re f i n i s h
Training curriculum is ASE-c e rtified under
the auspices of the CASE standard s .
Toyota has always taken an active role in
N AT E F. John Saia, Technical and Body
Training De velopment Manager at Toyo t a
Motor Sales, U.S.A., Inc., Torrance, CA, is
the current chairman of NAT E F. Ac c o rd i n g
to John, “This is an excellent way for body
shop managers to get invo l ved in their comm
u n i t y. They can provide their expert i s e
and help direct the educational quality for
f u t u re technicians.”
N ATEF is a re s o u rce that’s working to
help our industry and yo u r business. Check
out their Web site at www. n a t e f. o r g — o r
A S E ’s site at www. a s e c e rt.org. These are two
vital re s o u rces that allow you to play a vital
role in the quality of your future technicians.

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C O L LI S I O N R E PA I R T R A I N I N G C O U R S E PA C K A G E S
Each of these course packages are used exclusively at all Toyota Collision Repair and Refinishing Training Centers and are available as self-study
training packages for technicians performing collision repair and refinish operations. Each training package includes a technician reference guide,
video tape, and learning aid.
N A M E PA RT NUMBER M S R P
N A M E PA R T NUMBER M S R P
Toyota Paint 00400-10000 $31.95
Finish Repair (PFR)
Toyota Non-Structural Body 00415-10001 54.95
Repair Techniques (NBRT)
Toyota Color Matching 00415-10002 54.95
For Painters (CMFP)
Toyota Structural Body 00415-10003 54.95
Repair Techniques (SBRT)
Toyota Advanced 00415-10004 54.95
Painting Techniques (APT)
C O L LI S I O N R E PA I R I N F O R MAT I O N B U LL E T I N S
Collision Repair Information Bulletins (CRIB) provide Toyota body and paint technicians with the latest developments in collision repair and refinish.
Information is divided among the following topics:
• General information • Refinish equipment • Welding • Structural repair
• Electrical • Interior • Exterior • Alignment
N A M E PA R T NUMBER M S R P
CRIB Bulletins #1-41 00408-03000-01 $20.00
CRIB Bulletin #49 00408-03000-49 1.00
CRIB Bulletins #51-57 00408-03000-51-57 10.00
CRIB Bulletins #58-61 00408-03000-58-61 5.00
CRIB Bulletins #62-65 00408-03000-62-65 5.00
CRIB Bulletins #66-67 00408-03000-66-67 5.00
CRIB Bulletins #68-69 00408-03000-68-69 1.18
CRIB Bulletin #70 00408-03000-70 2.00
CRIB Bulletin #71 00408-03000-71 2.24
CRIB Bulletin #72 00408-03000-72 1.62
CRIB Bulletin #73 00408-03000-73 1.24
CRIB Bulletin #74 00408-03000-74 1.04
CRIB Bulletin #75 00408-03000-75 1.18
CRIB Bulletin #76 00408-03000-76 1.04
CRIB Bulletin #77 00408-03000-77 .82
CRIB Bulletin #78 00408-03000-78 .98
CRIB Bulletin #79 00408-03000-79 1.34
CRIB Bulletin #80 00408-03000-80 1.16
CRIB Bulletin #81 00408-03000-81 1.00
CRIB Bulletin #82 00408-03000-82 1.12
CRIB Bulletin #83 00408-03000-83 1.40
CRIB Bulletin #84 00408-03000-84 1.40
CRIB Bulletin #85 00408-03000-85 1.20
CRIB Bulletin #86 00408-03000-86 1.22
CRIB Bulletin #87 00408-03000-87 1.20
CRIB Bulletin #88 00408-03000-88 1.20
CRIB Bulletin #89 00408-03000-89 1.20
CRIB Bulletin #90 00408-03000-90 1.04
CRIB Bulletin #91 00408-03000-91 1.04
CRIB Bulletin #92 00408-03000-92 1.30
CRIB Bulletin #93 00408-03000-93 1.20
CRIB Bulletin #94 00408-03000-94 1.20
CRIB Bulletin #95 00408-03000-95 1.20
CRIB Bulletin #96 - Panel Bonding Adhesives
00408-03000-96 1.10
PRICES SUBJECT TO CHANGE WITHOUT NOTICE
Lexus Paint 00232-20000 $54.95
Finish Repair Package
Lexus Non-Structural Body 00232-20001 54.95
Repair Techniques (NBRT)
Lexus Structural Body 00232-20002 54.95
Repair Techniques (SBRT)
Lexus Color Matching 00232-20003 54.95
for Painters
Lexus Advanced 00232-20004 54.95
Painting Techniques
Introduction to Lexus 00232-20005 54.95
C O L LI S I O N R E PA I R S U P P O RT MAT E R I A L S
These manuals focus on the fundamental skills necessary to develop a qualified body or paint technician.
Each title is useful for:
• Quick reference guidelines • Fundamental repair information • Basic diagnostic and damage assessment
N A M E PA R T NUMBER M S R P
N A M E PA RT NUMBER M S R P
FUNDAMENTAL BODY REPAIR PROCEDURES
Fundamental Manual 00400-BRM00-2E $21.95
FUNDAMENTAL PAINTING PROCEDURES
Fundamental Manual 00400-BR024 $24.95
N A M E PA RT NUMBER M S R P
CRIB Bulletin #97 - SRS Airbag Component Replacement
00408-03000-97 $1.58
CRIB Bulletin #98 - 2000 Paint & Refinish Formulas
00408-03000-98 1.28
CRIB Bulletin #99 - SRS Airbag Component Replacement
00408-03000-99 1.54
CRIB Bulletin #100 - MR2 Spyder Color Codes
00408-03000-100 1.20
CRIB Bulletin #101 - Solara Convertible Color Codes
00408-03000-101 1.14
CRIB Bulletin #102 - Prius Exterior Colors
00408-03000-102 1.14
CRIB Bulletin #103 - SRS Airbag Component Replacement
00408-03000-103 1.46
CRIB Bulletin #104 - Prius Emergeny Response Guide
00408-03000-104 4.38
CRIB Bulletin #105 - RAV-4 Exterior Colors
00408-03000-105 1.14
CRIB Bulletin #106 - Sequioa Exterior Colors
00408-03000-106 1.14
CRIB Bulletin #107 - 2001 Paint & Refinish Formula Codes
00408-03000-107 1.34
CRIB Bulletin #108 - Highlander Exterior Colors
00408-03000-108 1.14
CRIB Bulletin #109 - SC 430 Exterior Colors
00408-03000-109 1.14
CRIB Bulletin #110 - SRS Component Replacement-Toyota
00408-03000-110 1.24
CRIB Bulletin #111 - SRS Air Bag Replacement-Lexus
00408-03000-111 1.24
CRIB Bulletin #112 - MY 2001 Lexus Colors
00408-03000-112 1.20
CRIB Bulletins 1-40, 41-107
00408-CRIB-Bindr 84.00
2001 Prius Emergency Response Guide
00400-OTH02-0U .83

*CP13 2/23/05 11:02 AM Page 6
CO LL I S I O N R E PAI R RE FE RE N CE G U I DE
The Collision Repair Reference Guide is a quick reference manual that provides information such as body dimensions, paint and refinish formula
codes, SRS component replacement guides, ECT diagnostic information and glass tint codes.
N A M E PA RT NUMBER M S R P
Collision Repair Reference Guide
1980-1999 00117-00540-00 $4.00
Toyota Collision Repair and Refinish Service Publications are an integral part of the Toyota philosophy of “fix it right
the first time.” This detailed repair information is designed to speed and simplify repair operations and improve the
quality of each repair.
CO LL I S I O N R E PAI R MA N U A LS
• Cutting and welding operations • Anti-rust treatment • Body component diagrams and illustrations
• SRS handling precautions • Body panel replacement • Electronic control unit (ECU) locations
• Body dimensions • Plastic body part identification
T O Y O TA MODEL Y E A R PA R T NUMBER M S R P
AVALON 2001-00 00400-BRM08-7E $14.45
1999-95 00400-BR046 14.85
CAMRY 2002 00400-BRM11-0U 9.80*
2001-97 00400-BR062-E 14.85
1996-92 00400-BR032 6.34
Coupe 1996-94 00400-BR043 5.39
Wagon 1996-92 00400-BR035 6.34
1991-87 00400-BRM01-0E 12.00
CELICA 2001-00 00400-BRM08-8E 8.62
Convertible 1999-94 00400-BR044 15.95
1993-90 00400-BR022 6.95
COROLLA 2001-98 00400-BRM07-1U 14.45
1997-93 00400-BR038 9.44
Sedan 1992-87 00400-BR012 15.00
All Trac 1992-89 00400-BR014 2.83
Wagon 1992-89 00400-BR013 1.60
CRESSIDA 1992-89 00400-BR016 3.95
ECHO 2001-00 00400-BRM08-9E 14.49
HIGHLANDER 2001 00400-BRM10-3U 16.25
LAND CRUISER 2001-99 00400-BRM08-0E 14.45
1998-95 00400-BR050 11.95
MR2 2001 00400-BRM09-2E 8.95
1995-91 00400-BR025 6.95
LEXUS MODEL Y E A R PA R T NUMBER M S R P
ES 250 1991-90 00245-BRM01-8U $11.22
ES 300 2000-97 00245-BRM06-4E 14.85
1996-92 00245-BRM03-1U 6.34
GS 400/300 2000-98 00245-BRM07-4E 13.36
GS 300 1997-93 00245-BRM04-0E 8.10
IS 300 2001 00245-BRM09-7U 14.31
SC 400/300 2000-92 00245-BRM02-8U 6.34
SC 430 2002 00245-BRM10-4U 15.95
*Will be available early September, 2001.
T O Y O TA MODEL Y E A R PA RT NUMBER M S R P
PASEO 1998-96 00400-BR056 $8.91
1995-92 00400-BR030 6.34
PREVIA 1997-91 00400-BR027 10.00
PRIUS 2001 00400-BRM09-6E 14.95
RAV4 2001 00400-BRM09-8E 13.95
2000-96 00400-BR045 11.95
5-Door 1998-96 00400-BR052 8.91
SEQUOIA 2001 00400-BRM10-1U 17.95
SIENNA 2001-98 00400-BRM07-2U 14.49
SOLARA 2001-99 00400-BRM08-2U 8.62
Convertible 2001 00400-BRM09-3U 8.62
SUPRA 1998-93 00400-BR042 10.13
1992-86 00400-BRM00-5E 3.97
TACOMA 2001-97 00400-BR068 8.91
Double Cab 2001 00400-BRM10-2U 5.95
TERCEL 1999-95 00400-BR047 6.95
1994-92 00400-BR029 6.34
Sedan 1991-87 00400-BRM00-7U 12.58
Coupe 1991-87 00400-BRM01-1U 7.90
TUNDRA 2000 00400-BRM08-5U 8.62
T100 1998-97 00400-BR067 8.91
4RUNNER 2000-96 00400-BR060 14.85
N A M E PA R T NUMBER M S R P
Collision Repair Reference Guide
2000 Supplement 00117-00540-00SUP $2.00
C r e d it Ca rd To l l - F r e e O r d e r i n g
You may order all materials by phone. Please have your order prepared and your credit card handy when calling our
operators. Call between the hours of 7:00 a.m. and 4:30 p.m. PST at 1-800-622-2033.
PRICES SUBJECT TO CHANGE WITHOUT NOTICE
AVAILABLE TOYOTA SERVICE PUBLICAT I O N S
LEXUS MODEL Y E A R PA RT NUMBER M S R P
LS 400 2000-95 00245-BRM04-9E $14.85
1994-90 00245-BRM01-7U 4.72
LS 430 2001 00245-BRM09-9E 17.95
RX 300 2000-99 00245-BRM07-7U 26.17
LX 450 1997-96 00245-BRM05-3U 9.71
LX 470 2000-98 00245-BRM07-9E 14.45

*CP13 2/23/05 11:02 AM Page 7
&
Sowing the Seeds
The National Automotive Technicians Education Foundation
Setting the Standards
One of the biggest challenges facing the collision repair industry is where the next generation
of technicians will come from, and how skilled they will be when they arrive. Whether it’s a technician
finding the cause of a diagnostic light or one replacing a damaged “B”-pillar, modern vehicles are becoming
increasingly sophisticated. This intensifies the challenges for the schools and instructors preparing the
autobody technicians of tomorrow.
V
irtually everyone in this industry is
familiar with the National Institute
for Au t o m o t i ve Se rvice Exc e l l e n c e
(ASE) as the organization that cert i f i e s
technicians. But few know who cert i f i e s
the education institutions and the instructors
who train autobody technicians.
What is NATEF?
It is a division of ASE known as the
National Au t o m o t i ve Te c h n i c i a n s
Education Foundation (NAT E F).
N AT E F ’s mission is to evaluate entry -
level technician training programs against
s t a n d a rds developed by the automotive
i n d u s t r y and recommend qualifying
programs for certification by ASE. Using
the NATEF process, ASE certifies the
e n t ry - l e vel vocational training pro g r a m s
at over 1,500 schools nationwide. Each of
those schools is carefully evaluated to
e n s u re strict standards are met and the
proper skills are taught.
N ATEF sets standards in three
specialty areas:
• Automobile standards—automotive
repair training programs.
• Autobody standards—collision
repair and refinish education.
• Medium/heavy-duty truck
program—commercial
vehicle training programs.
The purpose of the Collision Re p a i r
and Refinish Training Cert i f i c a t i o n
Program is to improve the quality of
training offered at the secondary and
p o s t - s e c o n d a ry levels. NATEF does not
endorse specific curricular materials, nor
provide instruction to individuals, groups
or institutions. NATEF does, however, set
s t a n d a rds for the course content. T h o s e
standards are:
1 . Pu r p o s e . The collision repair and
refinish technician training pro g r a m
should have clearly stated pro g r a m
goals related to the needs of the
students and employers serve d .
2 . Ad m i n i s t r a t i o n . Program adminis-
tration should ensure that instru ctional
activities support and pro m o t e
the goals of the pro g r a m .
3 . L e a rning Re s o u rc e s . Su p p o rt material
consistent with both program goals
and performance objectives should
be available to staff and students.
4 . Fi n a n c e s . Funding should be prov i ded
to meet the program goals and
p e rformance objective s .
5 . Student Se rv i c e s . Systematic pre -
admission testing, interv i ews, counseling
services, placement and follow - u p
p ro c e d u res should be used.
6 . In s t ru c t i o n . In s t ruction must be
systematic and reflect program
goals. A task list and specific perf o rmance
objectives with criterionre
f e renced measures must be used.
7 . Eq u i p m e n t . Equipment and tools
used must be of the type and quality
found in the re p a i r i n d u s t ry and
must also be the type needed to
Continued on page 12
3

*CP13 2/23/05 11:03 AM Page 8
4
The Toyota
Production System
How It Evolved, What It Means to Body Shops
What do the collision repair industry and the
Toyota Production System (TPS) have in common?
For starters, both are constantly changing and evolving in response to technology
and customer demand. Moreover, as a framework for providing customers with high-quality work
and prompt, efficient service, TPS provides the precise elements that help body shops thrive in a
competitive environment.
TPS
was actually created to stre a mline
the automobile pro d u c t i o n
line, but its principles of eliminating
waste, raising efficiency and incre a s i n g
quality are just as effective outside the factory.
In the body shop, for instance, ordering part s
on a “just in time” basis eliminates exc e s s
i n ve n t o ry. Flexible repair scheduling ensure s
the time a customer is without their vehicle is
re p re s e n t a t i ve of the actual repair time. And
the use of standard i zed parts and repair proc
e d u res enhances both efficiency and quality.
Tracing the Roots of TPS
Early automobile plants we re craft
shops with individual workers putting
together entire assemblies by thems
e l ves. One at a time. But automobiles
built in this manner we re too expen-
s i ve for the mass market because
they took too long to build.
After the first World Wa r,
He n r y Fo rd and Ge n e r a l
Mo t o r s’ Alfred Sloan move d
world manufacturing fro m
centuries of craft pro d u c t i o n
into the age of mass pro d u c-

*CP13 2/23/05 11:04 AM Page 9
tion. It’s in the historic manufacturing
system developed by He n ry Fo rd
that we find the roots of TPS.
Ford’s system introduced three dist
i n c t i ve elements to the automobile
plant. Conve yor belts that move d
cars t h rough the assembly pro c e s s ,
bringing work to the workers instead
of vice versa. Craft production was
replaced by dividing the assembly sequence into simple, repetitive
tasks arrayed along a production line. And an integrated
supply chain for parts and materials was created to keep each
p rocess in the production sequence supplied with what they
needed. Additionally, to ensure production kept moving, Ford
began using standardized interchangeable parts.
Kiichiro Toyoda (son of Toyota’s founder, Sakichi Toyoda)
visited America to study Fo rd’s manufacturing system.
Inspired by Ford’s innovations enabling mass vehicle production,
he decided to adapt these ideas to Toyo t a’s pro d u c t i o n
line in Japan.
Production volumes in Japan, howe ve r, we re minuscule
compared to North America. So Toyoda sought flexible methods
for adapting the same machines to different vehicle models.
He also ensured each process in the assembly sequence was
provided only with the kinds and quantities of parts needed,
when they were needed. And each process along the line produced
only the items needed by the next. This was the beginning
of “just in time” production. Toyoda’s colleague, Taiichi
Ohno, then drew further inspiration for TPS from the
American supermarket. He created a production line where
each process became the “customer” for the previous process
and a “supermarket” for the process ahead.
The Beauty of TPS
While TPS was based on Fo rd’s system, there are
significant differences between “mass production” and Toyota’s
system. Mass production typically uses unskilled workers and
K i i c h i ro Toyoda (son of Toyo t a’s founder, Sa k i c h i
Toyoda) visited America to study Fo rd’s manufacturing
system. Inspired by Ford’s
innovations enabling mass vehicle
production, he decided to
adapt these ideas to Toyo t a’s
production line in Japan.
single-purpose machines
to churn out standard i ze d
p roducts in high vo l u m e .
Machinery is expensive and
intolerant of disruption, so
standard designs are kept in
production as long as possible.
Customers re a l i ze gre a t
cost savings as opposed to
craft production, but at the
expense of product variety. Work methods tend to be boring
and dispiriting for workers.
In contrast, TPS combines the advantages of craft and mass
p ro d u c t i o n — m o re cost-effectively than craft production and
m o re flexibly than mass production. Teams of multi-skilled
w o rkers are employed at all levels of the organization.
Together with automated, highly flexible machines, they produce
volumes of products in enormous variety.
One of the most dramatic differences between mass
production and TPS, however, is in their ultimate objectives.
Ma s s - p roducers set goals translating into a narrow range of
standardized products and an acceptable level of defects. TPS,
on the other hand, is focused solidly on perfection.
What makes this focus possible is maintaining a continuous
f l ow of products that can adapt to changes in demand.
This flow, called “just in time” production, produces only the
necessary units at the necessary time. Without excess inventories
and work, increased productivity and cost re d u c t i o n s
come naturally. “Just in time” production is also
interdependent with three key objectives:
• Quantity control enabling constant adaptation to
Continued on page 11
5

*CP13 2/23/05 11:06 AM Page 10
6
Training and Education
1 Toyota Supports High
School Education
2 Toyota Supports College
Education
3 Toyota Provides
Professional Training
4 Toyota Certifies
Collision Repair
Technicians
Support Materials
[1]
1 Fundamental
Procedure
Manuals
2 Vehicle Repair
Manuals
3 Collision Repair
Reference Guides
4 Collision
Repair
Information
Bulletins
[2]
[4]
[1]
[4]
[2]
[3]
[3]
[4]
[3]
Collision Center Certification
95
80
[2]
1 Pursuit of 100%
Customer
Satisfaction
2 Body Shop
Certification
3 Process
Consultation
4 Efficient
Management
Customer Service Index
To y o t a Sup p
the Collisio n
Genuine Toyota Parts
1 Genuine
Toyota Parts
Consistency—
supports
body shop
efficiency
[1]
[1]

*CP13 2/23/05 11:06 AM Page 11
Toyota has great re g a rd for the collision
repair industry as one of its key business
p a rtners and actively supports this
i m p o rtant partnership in a variety of
ways. These include a full line of parts, re p a i r
s t a n d a rds, body shop certification, and
technician training and certification. Here ,
Collision Pro s p rovides an overview of the
s u p p o rt Toyota provides for its valued body
shop part n e r s .
Fixing It Right the First Time...
with the Right Parts
Genuine Toyota Parts are manufactured to the
same exacting standards as the parts installed on
new Toyota vehicles. This helps ensure that Genuine
Toyota Parts will consistently fit like the part s
that were installed when the car was built. This
helps take the guesswork out of how long it will take
to install replacement parts and helps improve the
p roduction process.
up p o rting
Know It Right the First Time...
with the Right Repair Information
In addition to offering a full line of collision re p a i r
p a rts, Toyota provides a broad spectrum of publications
that detail Toyota repair standards.
The first steps toward understanding To y o t a
repair pro c e d u res are the Fundamental Body
Repair Pro c e d u re Manual and the Fundamental
Painting Pro c e d u re Manual. These
publications provide a foundation for understanding
how to repair Toyota vehicles, and
act as a basis for better understanding
vehicle-specific repair manuals.
Building on the Fundamental manuals,
Toyota offers Vehicle-Specific Repair Manuals
for Collision Damage. These manuals contain:
• Factory welding procedures
• Jacking and hoisting information
• Body panel removal and replacement
procedures
• Cut and join locations
• Location of High-Strength Steel (HSS)
• Location of Galvanized steel, corrosion
protection and sealer application areas
• Types of plastics used and their locations
on the vehicle
• Sound-deadening material placement
• Body dimensions
While the manuals explain procedures,
Collision Repair Information Bulletins (CRIBs)
a d d ress policy and procedural issues. For
example, CRIB #96 details To y o t a ’s off i c i a l
position on “panel bonding” or “weld bonding,”
which is not an approved pro c e d u re .
CRIBs also contain consolidated inform a t i o n
not easily found in other sources, like
Supplemental Restraint System (SRS) component
replacement and To y o t a ’s policy on
repairing High-Strength Steel.
Also available is the Collision Repair
R e f e rence Guide (CRRG) which feature s
specifications on Toyota vehicles including:
• Body dimensions
• SRS component replacement
information
• Wheel alignment specifications
• Glass tint codes
• Paint and finish formula codes
• ECT diagnostic information
Both the 1999 CRRG and the 2000 supplements
are currently available. Together, these
two reference books provide information on
all Toyota vehicles built from 1980 through the
2001 Sequoia.
i sion Repair Indu s try
From Parts to Performance
All of these publications are available thro u g h
Toyota dealerships, or through the To y o t a
Material Distribution Center at 1-800-622-2033.
Learn It Right the First Time...
with Technical Training and
Certification
Toyota also supports Collision Repair
Technicians at two state-of-the-art collision
repair and refinish training centers located in
To rrance, California, and West Caldwell, New
J e r s e y. Training instructors average 17+ years
of collision industry experience, with up to nine
years of experience teaching at Toyota training
facilities. To ensure technicians learn techniques
and pro c e d u res they can use immedia
t e l y, programs are developed and enhanced
based upon technician input and re a l - w o r l d
p r a c t i c e s .
Technicians who participate in the training
program experience training that includes
extensive hands-on lab activity and classroom
instruction. Both laboratories are outfitted
with state-of-the-art equipment and classes
are taught using the most contemporary
techniques, tools and equipment on actual
Toyota vehicles. Technicians return to their
shops with information they can use immediately—and
their employers may realize
increases in productivity, reduced cycle time
and improved customer satisfaction.
Build Careers Right the First Time...
Encourage Careers in Automotive
Repair
N u rturing careers in collision repair is
another area where Toyota is active. This
begins with the support of high school
education, through To y o t a ’s support of the
Automotive Youth Education System (AY E S ) .
The program helps fund high school vocational/technical
programs that encourage
and pre p a re young people to pursue
c a reers in automotive re p a i r.
Toyota also sponsors the Toyota Te c h n i c a l
Education Network (T-TEN), which supports a
series of junior college collision repair training
p rograms. T-TEN programs help improve the
skills of entry-level technicians by teaching
automotive theory and practical hands-on
repair techniques.
Confirm It’s Right the First Time...
Body Shop Certification
The Toyota Certified Collision Center
(TCCC) program was developed in 1996.
This program, currently available only to
Toyota dealerships, sets stringent certification
standards and includes an intensive management-consulting
program to help shops
achieve these standards.
One of the key skills taught and re i n f o rc e d
during the certification process is the importance
of writing a thorough and correct estimate
when the vehicle first arrives in the shop.
This helps increase shop pro d u c t i v i t y, impro v e
the on-time delivery rate and, most import a n tl
y, helps ensure that all factory - re c o m m e n d e d
repair pro c e d u res are included.
TCCC dealers have an average 9.4 customer
s e rvice index (CSI), compared to an Autochex
average figure of 9.1 for the rest of the indust
ry. More import a n t l y, certified dealers achieve
an on-time delivery rate of 90 percent for
TCCC dealers versus an industry average of
78.2 percent.
Fixed Right the First Time...
On Time Collision Repair
In addition to the standard cert i f i c a t i o n
p rocess, TCCC dealers can implement
To y o t a ’s On Time Collision Repair (OTCR), a
system that adapts To y o t a ’s factory pro d u ction
principles to the body shop enviro n m e n t .
To d a y, OTCR shops are realizing quantifiable
i n c reases in body shop pro f i t a b i l i t y, steady
i n c reases in CSI and an on-time re t u rn rate of
95 percent for qualifying vehicles.
Toyota takes great pride in supporting the
collision repair industry—from a complete
inventory of Genuine Toyota Parts to
programs that increase knowledge, skills,
productivity, profits and performance.
7

*CP13 2/23/05 11:06 AM Page 12
On Time Collision Repair—
A Glimpse at the Future
With Toyota On Time Collision
Re p a i r, a number of Toyota dealers
have already seen into the
c rystal ball. As Jeff De b n e r, Body Sh o p
Manager at Fred Haas Toyota in Ho u ston,
Texas, says, “On Time Collision
Repair is the future of this business, and
if yo u’re not doing it today, yo u’re going
to miss the boat.”
Toyota On Time Collision Re p a i r — i f
the term is new to yo u — refers to dividing
a body shop into two lines. The On
[ 1 ]
8
Ever wish you could see
into the future? Would
you pick next week’s lottery
numbers and clean up?
Perhaps you would take a
look into the future and
see how businesses were
functioning in the future
and implement those
systems today.
On Time Collision Repair Process
[2]
Time line handles “light” repairs, while
the other line handles the “heavy”
repairs. The goal is to eliminate waste. By
splitting the repairs by type, jobs can be
assigned to the technicians most qualified
to perform a given re p a i r. This helps
i n c rease efficiency throughout the shop.
A major benefit of the Toyota On Ti m e
system is a target completion time of
t h ree days or less. And most dealers
w o rking the On Time system successfully
re p o rt meeting that goal virtually all of
the time (by comparison, the industry
a verage of meeting a promised delive ry
date is just 78 percent—while On Ti m e
dealers are averaging 95 perc e n t ) .
Bob Me l l i n g e r, Se r vice Di rector at
Lancaster Toyota, in Lancaster, Pe n ns
y l vania, agrees: “When we first start e d
with Toyota On Time Collision Re p a i r,
our customers thought we we re joking
when we told them when their car would
be re a d y.” Debner adds, “We’ve even had
customers mad at us—they come in to
pick up their car saying they put gas in
their rental car and we finished their
Vehicle Arrives
Toyota before they had a chance to use it.”
In fact, efficiency is quickly making
On Time Collision Repair a big hit with
consumers and insurance companies
alike. Debner notes, “Our customers are
constantly asking, ‘How’d you do it so
fast?’ They never thought a body shop
could be that efficient.”
Lancaster Toyota was one of the first
dealerships to pilot the Toyota On Ti m e
Collision Repair system. And as of Ap r i l
2001, they have been using it for one
ye a r. From an organizational standpoint,
initially eve ryone was skeptical. To d a y,
the results speak for themselves. Ove r a l l
business is up over 12 percent, with similar
gains in the parts department. And
e m p l oyee morale is soaring, too.
“When we first started, the technicians
we re n’t too sure how they we re
going to like it,” Mellinger says, “or if
they we re going to make any money. ”
Debner agrees: “When we went online
with Toyota On Time, I looked aro u n d
for some volunteers. After much effort, a
couple of guys said they would give it a
[3]
Tear Down
Body Work
[4]

*CP13 2/23/05 11:06 AM Page 13
[5]
t ry. Now, nine months later, our pro d u c-
tivity is way up…efficiency is up…and
the On Time crew members are making
good money. In fact, some of my other
technicians are now coming up to me
asking if they can switch to the On Ti m e
repair line.”
The key to the success of On Ti m e
Collision Repair lies in the organization.
Mellinger says, “T h e re is a definite set
of criteria to follow—and it’s amazing
h ow well it works. The biggest asset is
the way we evaluate each job that comes
into the shop. ”
With On Time Collision Re p a i r, a
client brings their damaged vehicle in for
an evaluation. If it meets the criteria for
On Time, then a date is set when the
customer will bring their vehicle back
into the shop. In the interim, the needed
p a rts are ord e red, primed and re a d y —
because if the parts are not in stock,
w o rk will not begin.
That way, once the technicians start
w o rking on a vehicle, nothing will slow
them down. T h a t’s why shops implementing
On Time Collision Repair are
able to get those repairs out in thre e
days—or less.
“As I have said in the past,” Me l l i n g e r
adds, “our ability to cycle ve h i c l e s
t h r ough the shop is being closely
watched by our local insurance compa-
Preparation
nies. Even they can’t believe how fast we
get vehicles in and out. And the more
efficient we are, that cuts the cost of
renting a car for their customer, which
helps keep the total costs dow n . ”
Debner agrees. With Toyota On Ti m e ,
i t’s not about working harder—but working
smarter: “Our profitability is way up,
p a rts sales are up and the technicians are
finding that they are earning more mon-
T W O C A S E S T U D I E S
Dealership Name: Lancaster Toyota
Dealership Location: Lancaster, Pennsylvania
Dealer Principal: Bob Allen
Body Shop Manager: Jan Jurell
Square Footage of Body Shop:
Main Shop: 24,510 sq. ft.
OTCR Shop: 9,500 sq. ft.
Total Number of Body Shop Employees:
Pre-OTCR: 33 Post-OTCR: 33
Body Shop Staffing by Position:
Production Coordinator: 1
Metal Techs: 16 Painters: 6
Estimators: 3 Support Staff: 7
Pre-OTCR Support Staff:
Production Manager: 1 Parts Person: 1
Detailers: 2 Office Support Staff: 3
Post-OTCR Support Staff:
Production Manager: 1 Parts Person: 1
Detailers: 2 Office Support Staff: 3
Number of Dedicated OTCR Staff:
Metal Techs: 1 Painters:1
OTCR Production Coordinator: 1
Average Monthly Repair Volume (Range):
Pre-OTCR: 320.1 Post-OTCR: 337.3
Productivity/Tech Efficiency:
Pre-OTCR: 131% (average per technician)
Post-OTCR: 285% (average per technician)
[6]
Paint
[7]
Reassembly
ey and they’re not overloaded on the job.
In fact, sometimes they are so efficient,
they run out of work. But thanks to our
m a rketing and our growing popularity
with the insurance companies, that doesn’t
happen too often.”
Looking back, it’s clear that the On
Time Collision Repair system works. It’s
quickly gaining supporters while helping
to shape the future .
Dealership Name: Fred Haas/
Fred Haas Collision Repair
Dealership Location: Houston, Texas
Dealer Principal: Fred Haas
Body Shop Manager: Jeff Debner
Square Footage of Body Shop:
Main Shop: 17,500 sq. ft.
OTCR Shop: 2,500 sq. ft.
Total Number of Body Shop Empoyees:
Pre-OTCR: 25 Post-OTCR: 25
Body Shop Staffing by Position:
Production Coordinator: 1
Metal Techs: 11 Painters: 2
Estimators: 3 Support Staff: 8
Pre-OTCR Support Staff:
Parts Person: 1 Detailers: 2
Office Support Staff: 3
Post-OTCR Support Staff:
Production Manager: 1 Parts Person: 1
Detailers: 3 Office Support Staff: 3
Number of Dedicated OTCR Staff:
Metal Techs: 1 Painters: 1
Production Coordinator: 1
Average Monthly Repair Volume (Range):
Pre-OTCR: 1741 Post-OTCR: 1901
Productivity/Tech Efficiency:
Pre-OTCR: 170% Post-OTCR: 240%
Detailing [8]
9

*CP13 2/23/05 11:06 AM Page 14
10
Tips
P r os Tips –
Cladding Colors
Style. It sets one model apart from
a n o t h e r. One of the best ways to add to
that style is by adopting two-tone paint
schemes. Today many Toyota models fea-
t u re this eye-catching color combination.
But it presents a challenge to the body
shop—when you repair the lower cladding
a reas, you may find that the color code on
the vehicle does not define the cladding
c o l o r. This article includes the cladding
i n f o rmation for 2001 Toyota models.
Cars are all about numbers. Displacement,
horsepower, wheelbase, VIN number.
And of greatest importance to the
body shop—color codes. The first challenge
is knowing where to find the color
code. On a Toyota, the vehicle paint code
is on the certification label, which is located
on the driver-side doorjamb or the lower
section of the “B” pillar. But finding the
code isn’t always enough because in some
instances, more information is required.
In those instances, you need to know
where to turn for assistance. One of the
body shop’s best resources is Collision
Repair Information Bulletin 00408-03000-
107. It contains all of the paint and refinish
formula codes for the 2001 Toyota models.
In addition, when new models are introduced,
Technical Service Bulletins (TSBs)
are produced. For example, in January,
TSB PA001-01 was published which
detailed the two-tone paint scheme used
on the 2001 Camry Gallery Series.
When repairing the cladding, remember
that these sections may receive various
anti-corrosion treatments or flex additives.
When repairing the vehicle, make sure
these sections are returned to preaccident
condition. Contact your paint
manufacturer for more information.
For further information about any of these vehicles, please
refer to the appropriate Repair Manual for Collision Damage.
Here are the cladding color codes for each model:
Tundra Two-Tone Combination:
COLOR CODE COMBINATION VEHICLE COLOR/TRIM COLOR
2FC 6Q7/1C7 Imperial Jade Mica/Thunder Gray Metallic
Camry Gallery Series:
COLOR CODE COMBINATION VEHICLE COLOR/TRIM COLOR
2HG 1B2/1C8 Antique Sage Pearl/Lunar Mist Metallic Accent
2HH 6R6/1C8 Mineral Green Opalescent/Lunar Mist Metallic Accent
2GF
Sequoia SR5:
051/1C8 Diamond White Pearl/Lunar Mist Metallic Accent
COLOR CODE COLOR NAME FENDER MOLDING, BUMPER,
RUNNING BOARD
COLOR NAME
056 Natural White UCAD7 Warm Silver
1D6 Silver Sky Metallic 1D6 Silver Sky Metallic
1C7 Thunder Gray UCAD7 Warm Silver
202 Black 1C7 Thunder Gray
3K4 Sunfire Red Pearl UCAD7 Warm Silver
4Q2 Desert Sand Mica UCAD7 Warm Silver
4Q7 Chestnut Pearl UCAD7 Warm Silver
6Q7 Imperial Jade Mica 1C7 Thunder Gray
8P9
Sienna XLE:
Blue Marlin Pearl 1D6 Silver Sky Metallic
COLOR CODE COLOR NAME CLADDING COLOR NAME
040 Super White UCAD8 Cool Silver
1D7 Silver Shadow Pearl UCAD7 Warm Silver
3N6 Vintage Red Pearl UCAD7 Warm Silver
3P5 Black Walnut Pearl UCAD7 Warm Silver
4Q2 Desert Sand Mica UCAD7 Warm Silver
6R1 Woodland Pearl UCAD7 Warm Silver
8L9 Denim Blue Mica UCAD8 Cool Silver
8N7 Sailfin Blue Pearl UCAD8 Cool Silver
8Q0
Land Cruiser:
Stratosphere Mica UCAD8 Cool Silver
COLOR CODE COLOR NAME BUMPER COLOR COLOR NAME
056 Natural White UCA46 Lt. Grayish Beige Metallic
1B1 Champagne Pearl UCA46 Lt. Grayish Beige Metallic
1C3 Riverock Green Mica UCA76 Medium Gray Metallic
1D2 Thunder Cloud Metallic 1D2 Thunder Cloud Metallic
202 Black UCA76 Medium Gray Metallic
3N2 Mahogany Pearl UCA76 Medium Gray Metallic
6Q7 Imperial Jade Mica UCA76 Medium Gray Metallic
8L4 Atlantis Blue Mica UCA76 Medium Gray Metallic
RAV4 “L” Package (P-molding):
COLOR CODE COLOR NAME
196
RAV4 EV:
Pewter Metallic
COLOR CODE COLOR NAME CLADDING COLOR NAME
040 Super White U1B9 Quicksilver Fx
1C0
4Runner SR5:
Millennium Silver Metallic U1B9 Quicksilver Fx
COLOR CODE COLOR NAME FENDER MOLDING COLOR NAME
056 Natural White 1C0 Millennium Silver Metallic
1D2 Thunder Cloud Metallic 1D2 Thunder Cloud Metallic
1C0 Millennium Silver Metallic 1C0 Millennium Silver Metallic
202 Black 202 Black
3K4 Sunfire Red Pearl 1D2 Thunder Cloud Metallic
587 Dorado Gold Pearl 587 Dorado Gold Pearl
6Q7 Imperial Jade Mica 6Q7 Imperial Jade Mica
768 Glacier Metallic 1D2 Thunder Cloud Metallic
8L7 Stellar Blue Pearl 1D2 Thunder Cloud Metallic
4Runner Limited (cladding and over fender):
COLOR CODE COMBINATION VEHICLE COLOR/TRIM COLOR
K72 056/1C0 Natural White/Millennium Silver Metallic
KG0 1D2/1C0 Thunder Cloud Metallic/Millennium Silver Metallic
KF8 1C0/1D2 Millennium Silver Metallic/Thunder Cloud Metallic
KG1 202/1D2 Black/Thunder Cloud Metallic
KG2 3K4/1D2 Sunfire Red Pearl/Thunder Cloud Metallic
KG5 587/1D2 Dorado Gold Pearl/Thunder Cloud Metallic
KG6 6Q7/1D2 Imperial Jade Mica/Thunder Cloud Metallic
KG7 768/1D2 Glacier Metallic/Thunder Cloud Metallic
KG9 8L7/1D2 Stellar Blue Pearl/Thunder Cloud Metallic
4Runner Limited (single color):
COLOR CODE COMBINATION VEHICLE COLOR/TRIM COLOR
KF9 1D2/1D2 Thunder Cloud Metallic/Thunder Cloud Metallic
K73 1C0/1C0 Millennium Silver Metallic/Millennium Silver Metallic
KG4 587/587 Dorado Gold Pearl/Dorado Gold Pearl