Toyota Motor Europe Facility Guide

II.3. Parts Related

II.3.A. General Plan
II.3.A.-.1. Flow Line and Layout Concepts

Design a layout to ensure an efficient flow for the following

processes: part arrival – handling – storage – shipping (for both
external and in-house sales)

* Designed for countries where drivers keep to the right side of the road

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II.3.A.-.2. Main points

Design a layout to ensure an efficient flow for the following

processes: part arrival – handling – storage – shipping (for both
external and in-house sales)

FACILITY MAIN POINTS REF.

PAGE
1 Parts Retail Counter Locate within easy access of the parts warehouse 82
2 In-house Sales Counter Locate inside the parts warehouse facing the general 82
service work area, and close to the job control counter
3 Wholesale Counter (External Sales Counter) Provide delivery space near to the warehouse arrival entrance 83
4 Parts Warehouse - Minimizing the technician flow is the first priority 83
- The height of the ceiling should be at least 2.5 m,
or at least 5 m if mezzanine racks are used
5 Parts Racks The required area is decided based on the UIO size 84
and the local situation
6 Parts Handling Area Provide an area near the receiving entrance of the warehouse where sorting and -
inspection can be performed
7 Parts Receiving Entrance Locate where it can be accessed from the vehicle roadway -
8 Warehouse Aisles Make wide enough so there are no obstructions to storing -
and picking operations

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 Toyota Motor Europe Facility Guide

II.3.B. Description by Area

II.3.B.-.1. Parts Retail Counter
Main Points
- Locate near to the parts warehouse and within easy access of
the lounge and cashier.

II.3.B.-.1.1. Parts Retail Counter

- Install a high counter that the parts reception and delivery
can be processed quickly.
- Install signs.

- Provide an electronic catalogue.

Electronic Parts Catalogue System

II.3.B.-.2. In-house Sales Counter

Main Points
- It should face the general service work area.
- Provide a space nearby to keep the special order parts rack
(pre-pulling bin).
- Provide office space nearby (to control part receptions and
deliveries).

II.2.B.-.2.1. Technician Counter

- Provide terminals on the counter for the electronic catalog
systems.

Workshop side

Parts warehouse side

II.2.B.-.2.2. Pre Pulling

- Organize a space for pre-pulling parts.

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 Toyota Motor Europe Facility Guide

II.3.B.-.3. Wholesale Counter (External Sales Counter)

Main Points
- Locate near to the parts warehouse.
- Provide parts delivery space close to the parts reception
entrance of the warehouse, in a location that is easy to access
for parts transportation vehicles.

II.3.B.-.3.1. Wholesale Counter

- Provide terminals on the counter for the electronic catalog
and microfiche reader systems.
The other specifications are the same as for the retail counter.

II.3.B.-.3.2. Delivery Counter

II.3.B.-.4. Parts Warehouse

Main Points
- Minimizing the workflow of staff is the first priority.
- Locate near to the service workshop.
- Locate within direct access of the vehicle roadway to facilitate
parts reception.

Zoning plan
- Part warehouse should contains systems that ensure effective
management, such as: Dealer Management System (DMS),
Dealer Communication System (DCS), Electronic Parts
Catalogue (EPC), Toyota customer database, Menu Pricing
(MP), technical library, parts follow-up system and customer
communication systems.
The follow-up control system allows the parts operation
control in accordance with New TSM requirements.
Electronic versions that fulfill these requirements will be
acceptable.

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 Toyota Motor Europe Facility Guide

Logistics Flow
- Just-In-Time logistics are based on the “Sell-One, Buy-One
Concept”.
- Logistics are linked to customer demand, ensuring they move
at the same pace.
- JIT is characterized by low stock volume, and frequent
ordering and supply.

II.3.B.-.4.1. Parts Warehouse

- The ceiling height should be at least 2.5 m, or at least 5 m if
mezzanine racks are used.
- Provide sufficient ventilation, lighting and waterproof
protection.

II.3.B.-.4.2. Parts Racks

- The maximum height of the racks should be about 2 m so
they can be easily reached by hand.
- Locate pre-pulling parts and fast moving parts near to the
shipping exit.

II.3.B.-.4.3. Parts Storage Area

The required area is calculated from the following factors.
(For the calculation standards refer to p 20 of “Vol. I: Basic
Planning”.
- UIO size
- Concentration of vehicles received for service (in-house sales
ratio)
- Order/delivery frequency
- Size of retail and wholesale sales (external sales ratio)
- Stocking policy (e.g. whether there is a body parts inventory)
- Others, e.g. national or local situation

II.3.B.-.4.4. Lockable Area

The warehouse must have a lockable area that allows overnight
dellivery.

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 Toyota Motor Europe Facility Guide

II.3.B.-.4.5. Parts Storage Area

- Locate where it can be accessed from the vehicle roadway.

- The height should be at least 2.5 m, with an opening width
at least 3.0 m.
- Retailers with greater ratios of external sales should have a
wider shipping exit or a separate exit, so that workers can
handle a large volume of parts.
- If a forklift is used for carrying parts, this should be considered
when determining the height of the entrance/exit.

II.3.B.-.4.5. Warehouse Aisles

- Construct main aisles and sub aisles.
- Make wide enough so there are no obstructions to storing
and picking operations.

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II.3.C. Reference
Sample Layout
1. Parts Receiving Entrance B : 100m2 Plan
2. Sorting Area
3. Temporary Storage Area
4. Shipping Exit to W / S
5. Shipping Exit to Counter
6. Special Orders
7. Pre - Picking
8. Small and Very Small Parts
9. Medium Parts
10. Large Parts
11. Body Parts

A : 150m2 Plan

C : 70m2 Plan

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 Toyota Motor Europe Facility Guide

II.3.C.-.1. Parts Racks

Main Points ,OCATIONNUMBER .OREN4AG
Toyota’s 7 Storage Techniques are designed to increase safety
and quality, and improve the efficiency of operations.
- Vertical storage
- Storage by product
- Heavy parts stored down low
- Separate location for each parts number
- Store within easy reach
- Irregularity control
- Storage by movement

For details refer to the TSM operation guide.

“Noren” tags are affixed to each rack. As a reference, typical part racks are
described below.

II.3.C.-.1.1. Racks for Very Small Sized Parts

- Store very small parts in boxes on the racks.
- The highest and lowest racks are for items such as non-stock
parts.
- Reference size: H (total height) x W (total width) x D (depth)
H 2,100 mm x W 1,800 mm x D 190 mm

II.3.C.-.1.2. Racks for Small and Medium Sized Parts

- Store small and medium parts in boxes on the racks.
- Reference size: H 2,100 mm x W 1,800 mm x D 480 mm

1 2 II.3.C.-.1.3. Racks for Belts and Batteries

- Store belts on the upper rack and batteries on the lower rack.
- Reference size: H 2,100 mm x W 1,800 mm x D 620 mm

II.3.C.-.1.4. Racks for Special Order Parts

- Store in boxes and buckets on the racks.
- Place vertical racks for long objects such as mufflers next to
these racks.
- Reference size: H 2,100 mm x W 2,475 mm (1,200 + 900 +
375) x D 620 mm

II.3.C.-.1.5. Racks for P-to-P Parts

- Store in buckets on the racks.
- Reference size: H 2,100 mm x W 900 mm x D 620 mm
3 4
II.3.C.-.1.6. Racks for Glass/Mufflers
- Racks for storing long objects from the P-to-P Parts such as
glass and mufflers.
- Reference size: H 2,100 mm x W 900 mm x D 770 mm

5 6

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