Toyota cuts costs and development times with PLM

Toyota Industries reckons it’s shaved development costs by 53% and development cycle time by 44% on its high pick forklift trucks project by harnessing product lifecycle management (PLM) systems from IBM and Dassault Systemes. The firm is also using Dassault’s Catia V5 CAD/CAM software and the firm’s Delmia manufacturing producitno simulation suite to develop and optimise production processes and to assist with factory machines and tools management. Toyota began using PLM solutions in late 2000 as part of its IT Propulsion programme aimed at improving business, engineering and manufacturing agility through the use of 3D data and improved information management and sharing. Catia V5 and Knowledgeware technology have helped the firm to achieve these goals not least by allowing the company to automatically combine standard designs with customer-specific requirements, allowing it to manage build-to-order, with many variations and options, more efficiently. Additionally, by using the collaborative functions of IBM PLM solutions, Toyota has been able to integrate its 3D forklift product information with its manufacturing processes and machine and people resources and, design and simulate virtual factories through Delmia. The firm is now to harness the SmarTeam collaborative engineering and PLM systems to connect development sites world-wide, integrate its environment for 3D models, 2D drawings, technical documentation and BoMs (bills of materials). “Our high-level product development know-how combined with pioneering PLM solutions have brought tremendous synergies to the development of the High Pick Lift,” says Kimpei Mitsuya, Toyota Global IT Division director. “We achieved our original targets both by shortening the High Pick Lift development period from 18 to 10 months and by reducing development costs by 53%. “In addition, this product won the ‘Japan Society of Industrial Machinery Manufacturer’s Award’ for its gentle curved design which was achieved thanks to CATIA V5’s 3D design functionalities.” “TICO’s success is a perfect example of how companies in the Fabrication and Assembly market can increase their competitiveness by using collaborative 3D product development solutions across all stages of the product lifecycle,” says Etienne Droit, vice president sales and marketing, Dassault Systemes. “[Our] 3D PLM technologies enabled a world leader in the forklift market to turn its implicit know-how into explicit knowledge, and in doing so, helped TICO improve its ability to innovate, cut costs, and shorten development time.” Beyond this, to establish paperless communication with its suppliers by the end of 2004, Totota has now established a Supplier Support Center at its Takahama Plant in the Aichi Prefecture. The centre is equipped with a collaboration room, where suppliers can hold digital design review meetings, as well as 3D CAD rooms for Catia training.