At Toyota Motor Manufacturing, Indiana, Inc. (TMMI) production trials for the Tundra, Toyota’s new full-size pickup are underway. Team members in each area have already achieved milestones and faced some challenges on their way to producing the first Toyota Tundra this December. Production trials, also known as US1A trials, began in late July and involve each of TMMI’s production areas -- Stamping, Body Weld, Paint, Plastics and Assembly.

In Stamping, the first part was stamped May 19, and the second trial is in process. According to TMMI Body Weld and Stamping manager, Dan Antis, this additional trial is to ensure that equipment is tuned and adjusted. The dies are also tested, so they are in good working condition and can produce the necessary parts to support the welding trials.

In Body Weld, the first official trial recently began on September 14. "Our goal is to achieve top quality while building 60 vehicles in three weeks," Antis explained. The second weld trial will begin on October 12, which will utilize parts from the second press trial.

Team members are also very busy in Paint. July 29 marked the delivery of the first TMMI painted vehicle to Assembly. There are many new team members in Paint, who have begun training with team leaders. Some of this training includes learning the techniques of polishing, spraying, finessing and sealing. Team leaders have also completed the creation of training manuals, which include in-depth information about each process.

Injection molding machines in Plastics have been installed and have begun shooting parts. The four main components that will be molded at TMMI include the bumper, right and left door inners and the instrument panels.

"Preparing for expansion is also a challenge, especially in Paint," said Randy Mason, manager of Paint and Plastics. "But were taking every precaution to avoid any type of contamination." In fact, Paint team leaders conduct a session on dirt and contamination awareness during New Hire Orientation. "It’s important that we educate our team members and heighten awareness on this topic," Mason said.

Assembly is the largest shop area and equally as busy with production trials. Assembly team leaders have built the first set of trucks (18 in all) and are preparing to train new team members who will be starting at the end of September. In addition to production trials, there are many other Assembly activities. Material for the trials needed to be received and checked in, so flow racks are being positioned line-side for material storage. Team members have simulated packaging on the racks and are positioning the parts ergonomically. They are also hanging tools line-side and setting up break areas.

"Overall, morale is high and team members and trainers alike have a great sense of pride in their work and accomplishments," Krueger said.

In addition to the manufacturing shops, Inspection is an area in the production organization. Inspection team members are located throughout each production area, performing patrol or inline inspections on parts and vehicles. The size of the Inspection area doubled in August, and will continue to grow in October. Currently, team members are supporting production trials in each shop, in addition to their ongoing training. These activities are giving the team members opportunities to improve their knowledge and skills daily.

"The initial production trials have been excellent learning experiences, as well as opportunities for team members to show their proficiency. I am very happy with the team members enthusiasm, safety focus and innovative ideas," said Debra Taylor, Inspection manager.

Each shop area is also very pleased and appreciative of the support and training they have received from the Japanese trainers. Communication can be challenging at times, but team members have developed friendships with the trainers that they maintain outside of work as well.