Download PDF

Case Studies > How Toyota leverages Appsheet to drive productivity at its manufacturing plant

How Toyota leverages Appsheet to drive productivity at its manufacturing plant

Technology Category

Platform as a Service (PaaS) - Application Development Platforms
Functional Applications - Remote Monitoring & Control Systems

Applicable Industries

Automotive

Applicable Functions

Quality Assurance
Product Research & Development

Use Cases

Predictive Maintenance
Machine Condition Monitoring
Remote Asset Management

Services

Software Design & Engineering Services
System Integration

The Challenge

Toyota’s assembly data was trapped in spreadsheets, making it difficult to share data across plants or upstream. The company needed an enterprise application to collect data from the assembly lines and create a central database. However, IT was unable to justify the resources to build an application from scratch for a user base of fewer than 100 people. Existing applications offered by Toyota developers were not equipped to meet the specific needs without significant revision and lacked a mobile interface crucial for data collection on the plant floor. This led to frustration among non-developer line-of-business users like ergonomist Ben Atkinson, who saw the potential for data to drive productivity improvements but faced obstacles in collecting it from mobile workers.

About The Customer

Toyota, a global leader in automotive manufacturing, is renowned for its commitment to lean production and continuous improvement. The company operates seven manufacturing plants across North America and is dedicated to optimizing its vehicle assembly process. Toyota's North American engineering headquarters is located in Lexington, Kentucky, where ergonomist Ben Atkinson oversees the collection and analysis of assembly line data to enhance productivity and worker comfort. The company is constantly seeking innovative solutions to streamline its operations and improve the quality of its vehicles, aligning with its philosophy of manufacturing excellence.

The Solution

Toyota turned to AppSheet, a no-code app development platform, to address its data collection challenges. AppSheet allowed Toyota to quickly create mobile-responsive apps without the need for developer time or upfront costs. The platform's intuitive interface enabled easy adoption, drawing data from existing spreadsheets and ensuring data protection and security. With AppSheet, Toyota could gather assembly line data on the fly, providing real-time insights into productivity and quality improvements. The platform facilitated seamless data collection and sharing across plants, enabling teams to make informed decisions based on up-to-date information. This approach aligned with Toyota's lean philosophy, allowing for rapid iteration and refinement of the app to meet the specific needs of the assembly process.

Operational Impact

AppSheet enabled Toyota to collect real-time data from the assembly line, providing up-to-date information to both assembly and design teams.
The platform facilitated seamless data sharing across Toyota's North American manufacturing plants, improving coordination and decision-making.
Toyota was able to minimize worker fatigue and discomfort by collecting and analyzing data on push force and comfort ratings for each part, leading to increased productivity and quality.

Quantitative Benefit

Toyota's assembly data collection process became significantly more efficient, reducing the time required to gather and analyze data.
The use of AppSheet eliminated the need for costly custom application development, saving Toyota substantial IT resources.
Real-time data collection and sharing improved decision-making speed, leading to faster implementation of productivity and quality improvements.