Embraer has expanded its agreement with Toyota do Brasil to apply the fundamentals and concepts of the Toyota Production System (TPS) in its industrial operations. Since June 2022, both companies have been collaborating to evaluate and suggest improvements in manufacturing at Embraer’s main factory, the Ozires Silva Unit, located in São José dos Campos, in the São Paulo state countryside.
The introduction of a new methodology implemented during a phase of the E-Jets commercial jet wings production has yielded a notable reduction of 50% in the manufacturing cycle. A 17% decrease was obtained in the total manufacturing time in wing production, contributing to an overall efficiency gain of approximately 20%. The Embraer Enterprise Excellence Programme (P3E) team will continue to expand the implementation of these collaborative initiatives with Toyota to other stages of wing manufacturing.
Due to the successful results, the two companies decided to expand the partnership for the joint development of other methodologies to be implemented at one of the stations on the E-Jets final assembly line.
“The application of TPS in Embraer’s production processes is yet another concrete example of how the methodology can contribute to more efficient operations, regardless of its field of activity, providing agility, quality and standardisation and directly impacting the competitiveness of the national industry,” highlighted Rafael Chang, President of Toyota do Brasil.
Embraer adopts the Lean philosophy as a core business strategy that disseminates P3E fundamentals, concepts and practices. This programme plays a pivotal role in orchestrating leading transformations, providing ways for the entire company to take leaps in improving its processes. This system also prioritises safety first, unwavering quality and consistent delivery timelines while maintaining optimal cost-efficiency. The company is committed to achieving carbon neutrality by 2024, achieving 100% of its energy from renewable sources for its Brazilian operations by 2024.