トヨタのモノづくり

トヨタ自動車の工場見学をする機会をいただいた。具体的にはトランスミッションを作っている衣浦工場である。モノづくりの現場に行ってみると、その過程のすごさをまざまざと見せ付けられる。

例えば、原材料のアルミを型に流し込むことで粗形材を作る過程では、空気が入ったりすることで小さな空洞ができる。小さな、というとどれぐらい小さいかというと、ほとんど肉眼では見えないレベルだ。その空洞があるとトランスミッションの故障の原因になるため、様々な工夫をして、今では空洞によるクレームはほぼゼロになっているそうである。

また、粗形材に部品を付けていく過程は、さながら精密機械工場である。そのラインに入るためには頭に帽子をかぶり、静電気を押さえる服を着て、靴も専用の靴を履く。そして、圧縮した空気によって服のゴミを取る部屋に入って全身からチリを取り除いてから入る。

入ってみると、そこでは様々な細かな部品を組み立てていくプロセスを見ることができる。面白いのはそのラインが結構止まることである。ビーっと鳴りラインが止まるとそのライン長がすぐに駆けつけて問題解決を図る。このように問題があればそれをすぐにオープンにして解決していくのだ。

「見える化」という言葉が最近世の中によく出ているが、その原点はやはりトヨタさんの工場である。しっかりとそのプロセスが行われていることに感心する。

　

自動車は約3万点の部品を組み合わせてできるそうだ。そして、車ごとにそれらの部品は違ってくる。従い、自動車を作る過程における作業は膨大な種類になる。

それらを日々の創意工夫の中で改善しているプロセスに触れることができて、大いに勉強になった。
　

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