Toyota manufacturer named “Top Plant”
Toyota Industrial Equipment Mfg., Inc. (TIEM) was named the 2010 "Top Plant" by Plant Engineering magazine. TIEM, the Columbus, Indiana-based facility, is the only manufacturer selected this year.
Plant Engineering's "Top Plant” is an award bestowed only to those manufacturers that achieve outstanding operational results—recognizing best practices in plant management, safety, productivity and efficiency to meet the challenges of an evolving global manufacturing environment.
By Craig Pearson
“The entire Toyota team can be proud of this achievement,” said Rob Reinders, Director of Toyota Canada Industrial Equipment Division. “From our perspective, this award confirms that the lift trucks we sell in Canada are manufactured at a facility that raises the bar and does so year after year.”
TIEM designs, manufactures and supplies Toyota lift trucks and replacement parts associated with industrial lift trucks and tow tractors, along with the assembly of motor vehicle parts and accessories. Today, nearly 80% of all Toyota lift trucks sold in North America are produced at TIEM, according to the company.
“We’re pleased to honour the Toyota forklift facility with the 2010 Top Plant award,” said Bob Vavra, Editor of Plant Engineering magazine. “Our editorial staff analyzed 24 pages of meticulous data, which clearly outlined the quantifiable measures that TIEM has put in place to achieve efficient automation processes while steadily improving its tremendous safety and environmental record. TIEM has demonstrated continuous incremental improvement during the last two decades. Their work sets a high standard of manufacturing excellence.”
TIEM was selected based on a number of manufacturing successes, including:
• Achievement of a “zero” landfill facility by shifting to a waste-to-energy facility
• Implementing an energy reduction program designed to reduce the carbon footprint of TIEM. In 2008, for example, TIEM achieved a 35.7% reduction in electrical usage and a 21.5% reduction in natural gas usage. Overall, TIEM reduced the facility’s carbon footprint by almost 4,000 tons of carbon dioxide in 2008
• As a result of regular associate and plant-wide OSHA and risk-assessment training sessions, safety incidents have been reduced by more than 65% and the ergonomic recordable rate by nearly 90%
• Incorporating a Total Plant Maintenance (TPM) program that reduced emergency repairs from 14% of total maintenance in 2008 to just 11% in 2009 and enabled the cost per hour of downtime to be cut by 10% in the same period.
TIEM’s 19 maintenance associates are tasked with checking hydraulic tank levels, cleaning filters, verifying lights working, etc. However, associates throughout the plant assist with maintenance. This program helps associates effectively monitor and maintain nearly 4,000 pieces of equipment throughout the plan.
For additional information about Toyota Lift Trucks, visit www.forklift.toyota.ca.