The why
Toyota Manufacturing UK: [[Automotive Efficiency]]
Toyota Manufacturing UK’s Burnaston Plant in Derbyshire transformed their liquid applied sound damping (LASD) material delivery process, aligning with Toyota Production System (TPS) principles of waste elimination and continuous improvement.
Their needs
The former solution was to discharge steel totes by using double ram press systems. Unfortunately, it left about 95 kg (209 lbs) of residual material per container and required 56 minutes for each changeover.
The tote and ram press system also included a cleaning process that consumed time and resources, and produced wastewater considered as problematic waste that required proper disposal.
The how
Their
[[Solution.]]
The sound dampening material is now delivered directly from the supplier to the vehicle manufacturing lines, in flexible 1000-liter Fluid-Bags. For an efficient discharge process, four automatic Discharge Rollers have replaced the double ram press systems.
Waste elimination
Residual waste per container dropped from 95 kg (209 lbs) to approximately 30 kg (66 lbs), directly supporting lean principles of absolute waste elimination. Although Toyota could reduce the residue to almost zero, the amount left functions as a safety margin, preventing air from entering the system.
Lean in practice
Container changeover time decreased from 56 minutes to 10 minutes, demonstrating continuous improvement in standardized processes and production efficiency.
Clean operations
The closed, single-use system with Fluid-Bags eliminates the need for wastewater treatment, prevents unpleasant odors, and ensures a clean, organized supply room.
The output
Toyota Manufacturing UK operates four automatic Discharge Rollers that have delivered consistent performance since 2007. The solution reduced changeover time by 82% while cutting waste by over 67%.
Single-operator bag changes and robust equipment streamline material handling throughout their manufacturing process. The implementation of this solution exemplifies TPS commitment to quality, efficiency, and waste elimination.
“Time needed to change to a new bag: 10 minutes. One person needed to change the bag. Waste per bag is reduced to approximately 30 kg (66 lbs). No wastewater product. Clean and tidy supply room. No odors. Robust reliable equipment. Excellent customer support and after sales service.” – Toyota Manufacturing UK
For more information about the car production process, take a look at this Toyota page.
Perks of using
our solution
Up to 1000 liters of possibilities
Down to less than 1% of waste
Over 2 million bags of precision
Customers in 65+ countries
More than 40 years of innovation
The solution eliminates 696 grease drums annually
The courage to [[squeeze through]]
Innovation meets resistance. And since 1984, we’ve been helping companies challenge the status quo and find better ways to handle liquids and semi-solids.
Our solution serve manufacturers and end-users across industries and products: adhesives, sealants, coatings, inks, lubricants, cosmetics, foods, pharmaceuticals, and more.
Maximal squeeze for minimal waste. Let’s pioneer together.
