Innovative Development Methodology Based on the Toyota Way

摘要

Since its foundation, Toyota has been innovating in each process of automobile production based on the ideas shown in the Toyoda Precepts. These innovations are not only innovations in the methodology for various development processes, but also in company philosophy models cultivated by development engineers during their daily job. These are known as the "Toyota Way" and its elements which include "Continuous Improvement", "Challenge", "Respect for People", "Genchi Genbutsu" and "Teamwork". Various technological innovations have already progressed in the process from engine development to production. Examples are the use of CAD (Computer Aided Design) and structure analysis based on 3D CAD data in hardware development, CFD (Computational Fluid Dynamics) and visualization techniques in combustion system development, MBD (Model Based Development), the related DOE (Design Of Engineering) and new algorithms in software development, as well as new production strategies linked to the new techniques mentioned above. The development of Toyota's direct injection gasoline engine (Toyota D-4 engine) originated from a precombustion chamber system in the 1970's with the aim of purifying the exhaust gases when the future of catalyst technology was unpromising. This technology could not be mass-produced, but could subsequently go on to the R&D of DISC (Direct Injection Stratified Charge). In 1996, the stratified charge lean combustion gasoline DI engine could then be launched as the first-generation Toyota D-4 engine. After the second-generation D-4 engine was developed, this technology has now acceded to the dual injection D-4 system (D-4S), which combines it with homogeneous charged stoichiometric combustion and port fuel injection. During this progress, innovative development methods have been used and improvements in production engineering have been carried out in the development of the injection system. Many engineers have been engaged in these technology developments with the Toyota Way as the key to realize technological progress and the improvement of products through these activities.