Parts are attached according to customer orders. In the assembly process, a conveyor moves at a certain speed and parts are assembled on the moving assembly line. Parts are attached according to customer orders, and since each customer's order is different, there are cars of different colors and shapes and with different parts on the conveyor. What is Toyota’s approach to making cars?   Toyota continually tries to provide its customers with good-quality cars more quickly and at a lower cost than before. To do this, Toyota uses the Toyota Production System to make cars most efficiently. It is a method that aims to eliminate all kinds of wastage. The Toyota Production System is built upon two pillars: “Jidoka” and “Just in Time.” Jidoka is a Japanese word and basically means, “Automation with a human touch,” and is a way of thinking that “prevents defective products from being produced by stopping equipment immediately when a problem occurs.” Just in Time “produces only what is needed by the next process in a continuous flow.” At each process, machines automatically stop the production line when they detect a problem, keeping defective products from moving down the production line. Based on this approach, machines do their part, but individual workers on the production line also take responsibility for their work. When they find a problem, they stop work immediately and solve the problem. Make only what is needed, in the needed amount, when it is needed. Only parts that have been used at the factory are reordered. Companies that make parts produce only what is needed, so they don’t have extra parts in storage. Toyota implements many innovations at its factories. This is to make higher-quality cars. If there is a delay in work or if an error or problem is discovered, workers can pull a cord strung along the assembly line to call for assistance. When the cord is pulled, the "andon" display board lights up and the team leader comes to help. The error or problem is fixed, and after making sure the part is assembled correctly, the car is sent to the next process. If the problem cannot be fixed in time, the assembly line is stopped and the car is not sent to the next process until it is fixed. Each car on the conveyor has a piece of paper attached that is called a Production Instructions Sheet. The information tells the workers what parts that car needs. Each customer's order is different, and by checking the Production Instructions Sheet, parts can be assembled without making any mistakes. All workers can suggest innovations to make work easier. That is why Toyota can make high-quality cars. The Ergonomic Seat is a special work seat at the end of a mechanical arm that allows team members to perform assembly work inside cars while sitting down. This eliminates stress on the back and helps workers to perform their work efficiently and easily. These lifts automatically adjust the height of the car on the assembly line. This makes it easier to assemble parts that go on the lower part of the car such as the bumpers. Screws, tools and other items needed for work are placed on these carts. The necessary items move together with the movement of the conveyor, eliminating wasteful movement when taking tools. The “chameleon” is an invention for taking out the necessary number of bolts needed to attach parts. Thanks to the device with a wire that has a magnet at the end, the workers don't have to confirm the types and number of bolts each time. The device looks like the tongue of a chameleon, which is used to catch insects, so it is called "the chameleon." When the wire comes close to the container with the bolts . . . The number of bolts needed stick to the magnets on the ends of the wires. After painting, the doors are removed to make the work easier. Team members install parts that go inside the car such as meters, air conditioning and audio parts while sitting in a Ergonomic Seat. This innovation makes it easier to perform the work.   Windows are handled using large suction cups. Two workers form a team and carefully install the windshield and rear window. Robots accurately apply the necessary amount of glue. Engines are transported from the engine factory in the order that the cars are placed on the assembly conveyor. The engines are heavy, so a machine is used to lift them up for mounting. Wheels are also attached by machine. Seats are transported from the seat factory in the order that the cars are placed on the assembly conveyor. A machine is used to put the seat inside the car and then a worker attaches it. Door parts are installed on the doors that were removed in the beginning on a separate line. These doors are then transported back to the assembly line and re-attached to the cars after all other parts have been installed.