Vehicles

Stamping

History

Year
Line
Processing technology
Die making
1937
Independent placement of stamping presses until 1954
Hand finishing after rough forming by stamping presses until 1954
Hand carving until 1954
1957
Line placement of 500-ton press
 
Milling-to-die model copying
Die making with master model as datum
1961
 
Side member parts integrated
 
1965
1,500-ton transfer press
 
 
1966
Semi-automation of existing 500-ton stamping line
Automated door press die
Die making by NC
1967
500-ton full-auto stamping line
 
 
1968
Full-automation of existing 800-ton stamping line
 
 
1969
 
 
Electric discharging
1973
 
Steps taken to allow use of high-strength steel sheets
 
1975
 
 
Toyota Production System introduced
1977
 
Steps taken to allow use of anti-corrosion steel sheets
 
1978
 
Technical study for surface distortion prevention measure (earning JSTP Aida Prize)
 
1980
 
 
CAD/CAM
1981
Automatic press die changeover
Practical application of die face CAD
 
Practical application of die structure CAD
1983
TAPHS for existing 400-ton manual stamping line
 
Die making FMS
1984
General-purpose auto-loader for 2,000-ton transfer press
 
 
1985
 
 
Free-form surface that does not need to be finished by hand
1986
Auto-loader for Class A line
Rotary cam prepared for mass production
TINCA5 developed and applied
High-speed and precision machines
1987
Class A transfer press
Integrated quarter panel and inlet structure
Die structure CAM system (by wire frame)
Class B transfer press introduced
Die quantity reduction activities
Caelum system
Production using laser bonding device introduced
1988
Electric 3-axis transfer
5-axis laser facility for prototype production constructed
In-division regular production of low-volume car (Soarer) commenced
Inter-process robot transfer system
Laser beam machine
Stable forming technology (by single cushion)
1989
FA system introduced
(e.g. automatic guided vehicle [AGV] and automatic rack)
Thick-coat galvanized steel sheets developed and applied
State-of-the-art CAD/CAM
Large laser bonding device introduced
Press-type doors
Opposing hydraulic-pressure press forming
Quarter-integrated side members
Super-large tryout press line
1990
Small-volume press production system for automobile body parts (Flexible Press System[FPS])
Aluminum press forming technology
Continuous unmanned high-speed machining line
Large 3-dimensional measuring machine (for panel and body measurement)
Production of integrated side member inner panel (laser welded blank)
TINCA7 developed and applied
”10-5” rust-prevention measure
1991
 
Development of lightweight body (aluminum body)
Die and panel measuring and analyzing system
Quantification technique for surface quality evaluation (Super i, rangefinder)
1992
Integrated body panel production system by laser welding
Single process for big-panel draw die
Segment-type cast steel trial
Integrated cowl sides
1993
FPS expansion (by laser cutting, roller hemming)
Commonized door impact beam parts
Complete fillet modeling and small pitch pick method
Production subsidiary introduces 3D auto-measuring machine
Direct cutting of Full Mold (FM) model
1994
Press noise countermeasures established
Long laser welded blank (for door inner)
Centralized correction trial for out-sourced dies
Blanking soft piling
Luggage inner secondary forming of rear-end ridgeline
Laser weaving equipment
1995
One-step FEM for initial study
3D solid design
All Toyota Study meeting for sheet metal forming simulation held
Trial production on new die-making line
1996
Class A module transfer press
 
 
1997
 
"Virtual trial" commenced (for formability and accuracy simulation)
TAM press die foundry (Indonesia) established
Commonized steel sheet specifications (for international procurement)
Simulation for design-surface evaluation
Flame-hardened cast iron (TGC600)
1998
Mash seam welder
Shallow-draw roof process (for epoch-making yield improvement and process shortening)
Large horizontal 5-axis machine
2-piece per stroke transfer production of fenders
1999
A0TR auto-loader (at Takaoka Plant)
Shape freeze technology with coining bead
Consecutively unmanned and high-speed machining technology (gantry machine)
New mash seam welder
NAVI system developed (for 3D measurement and analysis)
TOGO CAD/CAM applied (for full 3D design)
2000
 
Accuracy improvement technology for thin super-high strength steel parts developed
Support system for global production engineering (to enable simultaneous line-offs around the world)
Trial of design by production engineering and production
Near net-shaped castings for dies
Tabletop-type (T/T) hemming process developed
2001
 
Design of curved surface fillet by production engineering commenced
Parametric die design developed
Inter-process analyzing jig developed
High toughness/hardenable cast iron
Net shaping and module assembly applied
2002
 
Trial of super-short term preparation process (BRAD)
CATIA V5 trial (press die-making process)
Data base for production preparation information constructed
2003
Aluminum production line (at Motomachi Plant)
Establishment of aluminum mass-production technology promoted
 
Class A innovative, inter-process transfer robot
QA network assurance system
New forming method (shallow drawing process) for fender panels
Reinforced measures against press machine differences
2004
Large servo press for global application developed
Quality assurance by CAE simulation (All-Green Activities)
Virtual assembly simulation (for prevention of interference inside of die)
Class A innovative tandem line
Reduction of steel sheet variety promoted
Toyota FAW (Tianjin) Dies (TFTD) in China starts die production
Class B innovative inter-process transfer robot
2005
Production Engineering trial line (at Motomachi Plant)
Material flow measuring equipment for press draw developed
Quality built-in innovation process (for original dies)
Large (Class A) servo press
High-rigidity die structure developed
Repeat die-making technology established
2006
Innovative blanking line
Expanded use of lubricant-coated steel sheets (for inner panel)
Innovative press die structure (high-rigidity die structure)
TFTD expands die manufacturing plant in China and die exports
YAG laser welding equipment
Class A servo trial press introduced
CATIA/Dynavista introduced
2007
Midsize and small (Class B and Class C) servo presses
Behavioral analysis of die used to build in quality
Global application of innovative repeat die-making technology
P-BT2 logistics reform
Class C spreader (auto loader)
Data base of globally shared press die design information constructed
Press traceability activities
2008
High-tensile/thick plate blanking line developed
Digital fitting process for mass production developed and applied
Activities for creating absolutely best original dies (in terms of quality and lead time) commenced
Material cost reduction promoted (to improve yield, etc.)
2009
 
Use of scroll materials expanded (to improve yield)
Activities for die cost reduction
Lightweight cast iron die developed
Processes for side member outer reduced
High-speed and high-precision machines introduced
Non-spotting draw die process
Recycled/reuse dies
2010
Compact press machine developed
Bulging process for wheel house inner (to improve yield)
 
Simple and Slim die structure promoted

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