World Class Train the Trainer Projects

Toyota Case StudySarah Drew

The College

BrandsToyota UK, JCB, Rolls Royce, Johnson Controls, Unilever

and The Football Association

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Toyota - In the World • Toyota continued skills investment through the recession, despite

unfavourable economic conditions. • One of the world’s leading automotive manufacturers• Operates 75 manufacturing companies across 28 countries globally• Markets vehicles in more than 170 countries

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Deeside, North Walesengine manufacturing

Toyota Manufacturing UK Overview

• Start of production Sept 1992 • 484 employees• £700 million investment

Burnaston, Derbyshirevehicle manufacturing

• Start of production Dec 1992 • 2,786 employees• £1.15 billion investment

•Largest and most experienced plants in Europe•Toyota and BSDC - successful 10 year partnership•Youth Apprentices, 3000 adult workers

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Core philosophies

CHALLENGE

KAIZEN

GENCHI GENBUTSU

CONTINUOUSIMPROVEMENT

TEAMWORK

RESPECTRESPECTFOR

PEOPLE

Train the Trainers

College Toyota

Sustainable Workforce

Introduce new technology

3,000 Employees

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Working together

Role

Facilitated funding agreement

Supported with mapping activity – continuing to do so

Advice on developing higher level apprenticeship scheme

Role

Brought efficiencies into the qualification process

Motivated members to consider further education

Role

Intermediary between TMUK and awarding bodies

Provided master trainers

Trained TMUK members to become trainers

Managed quality & verification process

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Working together

• Aligned existing Toyota training to national qualifications – standardisation across plants

• Train and develop Toyota staff to become trainers• Bring different skills to the partnership to ensure both

sides develop and learn• BSDC trained Toyota trainers; Toyota trained college

trainers; working together; mutual strengths• Classroom based theory plus training in company on

the shop floor – business improvement projects• Together, the training team delivered 10000+

qualifications• Collaborated on new diploma for hybrid engineering

Benefits from the training intervention •Company performance improved in terms of quality, cost and delivery •Highly motivated work force •College capability increased in advanced manufacturing •College developed lean process for delivering education •New technology introduced into the UK

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Turning the corner

• Introduced Auris Hybrid Synergy Drive • supported by unique qualification

• Returned to lean, efficient manufacturing • (full time working and lean manning)

• Number of employee ideas (bottom up) has increased

• Cost reductions have placed them in a stronger position

• Significant quality improvement activitiesContributions from skilled, educated workforce=

stronger company

Thank you

sarah.drew@bsdc.ac.uk