Educating the Youth: Transferring Expertise to Future Rulers (Part 7)
In the heart of the Motomachi Plant, a diverse team of skilled technicians embarked on an exciting journey in the spring of 2022 – the restoration of a first-generation Crown. The project, which focused on recreating the iconic interior and exterior metal trim, as well as the lamp parts, presented a series of challenges that required a blend of innovation, craftsmanship, and advanced materials.
One of the key obstacles faced by the team was the condition of the existing plastic tail lamp covers. Most of them were cracked with age and could not be reused, necessitating the creation of new ones from scratch. Materials team leader Shuji Shudo, project member Shinji Tanaka, and junior Raw Material Development Division staff worked tirelessly to overcome this hurdle.
Tanaka, in particular, faced another major challenge in reproducing the lamps: the plastic colour. Through repeated trial and error, he managed to reproduce the original tail lamp and turn signal hues by tweaking the amount of colouring material mixed into the resin in 0.1-gram increments.
However, problems with air bubbles in the molded parts persisted. The Raw Material Development Division, with its technology and expertise for eliminating air bubbles, proved invaluable. Tanaka, working closely with Ats from the division, was able to eliminate air bubbles by adjusting aspects such as the mold shape and cooling method.
Another hurdle was the use of metal alloys, such as zinc alloys, which shrink more than cast iron or aluminum alloys as they solidify, causing defects. To overcome this, the team employed a new metalworking technique known as incremental forming to rebuild corroded panels.
To ensure a nice finish, the team stretched out welding rods made from antimony, reducing their diameter from 1.6 mm to 0.3 mm, and then laser-welded part surfaces to fill holes. This meticulous process was crucial in achieving the "better-than-new" quality the team aimed for in the restoration.
The project was not just about restoring a car; it was about preserving Toyota's rich heritage and passing down the skills and knowledge to the next generation. Veteran and young employees worked together, with the contribution of junior employees being one of the project's key objectives. Shudo expressed gratitude for the cooperation and hard work of the Raw Material Development Division's junior staff in procuring the necessary parts.
The specific technologies and processes used by Toyota for the first-generation Crown restoration project are not detailed, but the company's focus on innovation, craftsmanship, and advanced materials suggests that these elements could be integral to creating decorative parts and lamps for such projects.
Toyota's broader practices in material development and restoration techniques, such as the use of recycled plastics, advanced gravity separation technology, and 3D printing, could potentially be applied in restoration projects for decorative parts requiring durable materials. The company's emphasis on craftsmanship, with skilled technicians like Hideki Kato focusing on passing down skills such as mold polishing, is also crucial for restoring decorative parts.
In conclusion, the first-generation Crown restoration project at the Motomachi Plant is a testament to Toyota's commitment to innovation, craftsmanship, and preserving its rich heritage. The project not only restores a piece of Toyota's history but also serves as a platform for passing down skills and knowledge to the next generation.
- Despite the challenges in reproducing the original plastic tail lamp colors, project member Shinji Tanaka was able to find a solution by working diligently to adjust the amount of coloring material in the resin.
- To overcome the issue of metal alloys, such as zinc alloys, shrinking more than other materials during the solidification process, the team employed a new metalworking technique called incremental forming.
- The Raw Material Development Division, with its expertise in technology and eliminating air bubbles, played a crucial role in solving the problems with air bubbles in the molded parts.
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