{"id":11019,"date":"2022-08-16T17:39:28","date_gmt":"2022-08-16T08:39:28","guid":{"rendered":"https:\/\/www.japanunix.com\/en_new\/wp\/?post_type=casestudy&p=11019"},"modified":"2023-05-02T12:42:25","modified_gmt":"2023-05-02T03:42:25","slug":"%e3%83%88%e3%83%a8%e3%82%bf%e8%87%aa%e5%8b%95%e8%bb%8a%e6%a0%aa%e6%a7%98","status":"publish","type":"casestudy","link":"https:\/\/www.japanunix.com\/en\/casestudy\/toyota\/","title":{"rendered":"TOYOTA MOTOR CORPORATION"},"content":{"rendered":"
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Toyota Motor Corporation adopts IPC for standards of Soldering visible Quality<\/h2>\n

New technology standards with IPC added to internal standards for further global expansion<\/h3>\n<\/div>\n
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Toyota Motor Corporation officially adopted IPC, an international quality standard for solder and mounting technology, for solder appearance standards in the newly created Toyota Standards (TS) in 2021. The company has created a new solder appearance standard with IPC at its core, replacing the previous in-house standard. We interviewed a person in charge of the Control Electronics System Development Department about the purpose, background, and aims of the project.\n<\/p>\n<\/div>\n

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Company Name<\/th>\nTOYOTA MOTOR CORPORATION<\/td>\n<\/tr>\n
Founded<\/th>\nAugust 28th, 1937<\/td>\n<\/tr>\n
Gross Sales<\/th>\n29.93 trillion yen (FY2020)<\/td>\n<\/tr>\n
Number of employees <\/th>\n74,132 (consolidated 359,542) <\/td>\n<\/tr>\n
Business<\/th>\nProduction and sales of automobiles<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<\/div>\n
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Download<\/div>\n
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To learn more, click here to download the PDF file.<\/p>\n

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Case Studies of IPC (Full Version)<\/a><\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n
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How IPC was adopted as an internal standard<\/h2>\n<\/div>\n
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Toyota Motor Corporation
\nElectronics Control System Development\u00a0Div.\u00a0<\/p>\n

Development Process & Quality Innovation Dept.
\nMr. Masahiro Ishikawa<\/p>\n

Electronic Performance Development & Engineering Dept.
\nMr. Hisao Nishimori<\/p>\n<\/div>\n<\/div>\n<\/div>\n

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Would you introduce about your roles in the company?<\/h3>\n

We, both of us belong to design and development division in Toyota. The Development Process & Quality Innovation Department is taking care of overall design quality and in charge of determining the standard of soldering visual quality of electric and electronic components. The Electronic Performance Development & Engineering Department is in charge of developing some electronic performance in the vehicle, and one of them is a test method of \u201cDurability Test for Solder Joint\u201d. On the other hand, the \u201cSoldering Production Quality\u201d is controlled by the Quality Assurance division. We would like to talk about the \u201cvisual criteria affecting the Standard of Soldering visible Quality\u201d, that is managed with design and evaluation point of view. <\/p>\n<\/div>\n<\/div>\n<\/div>\n

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How did you ensure the soldering quality before? <\/h3>\n<\/div>\n
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In Toyota, we recognize that soldering and its quality are the key reliability factor, and we have been established and maintained Toyota\u2019s original quality standards for more than 30 years. We have ensured the soldering reliability and design quality while revising those standards year by year.<\/p>\n

Toyota issues required design quality specifications to suppliers, and suppliers develop and deliver products based on our requirements. And then, the Quality Assurance Department of Toyota headquarters\/manufacturing sites ensure the soldering production process and quality at each supplier plants. In order to secure soldering quality, Toyota think about two pillars which are the design quality and the production quality, and Toyota achieved total soldering quality with those two pillars.
\nHowever, due to globalization, our supply chain also expanded with overseas suppliers, and we faced a significant gap with new suppliers, especially Production Assurance and Quality Control Department at factories were advised like \u201cWe cannot disclose items and criteria that Toyota does not require\u201d. <\/p>\n

Therefore, we have been discussing with Quality Assurance Department to change the process of working procedures since 2010. As spoked earlier, Toyota provides required specifications to our suppliers from our design divisions. In that process, we changed our process that \u201cIn addition to the soldering reliability requirement, Toyota requires its visual (appearance) standards at the same time.\u201d <\/p>\n<\/div>\n<\/div>\n<\/div>\n

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What were the criteria you established at that time? <\/h3>\n

Toyota had in house electronics product and assembly lines; thus, the initial Toyota Standards were referred to JIS, IPC and the internal standard which was used at that plant. However, when releasing the initial standards, many suppliers asked us that \u201cSo, how is this Toyota Standards relevant to IPC?\u201d. Then, we recognized IPC had become the substantial standard in the global automotive industry, and we began to study and started considering the new revision referring with IPC-A-610.
\nWe had a policy that Toyota is going to adopt common standard in the world, and according to the issues of J-STD-001 \/ IPC-A-610 Automotive Addendum, we launched new Toyota Standards of soldering visual quality, which was referred to IPC standards in Feb 2021.<\/p>\n<\/div>\n<\/div>\n<\/div>\n

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New Solder Appearance Standards Incorporating IPC Welcome from Suppliers
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With the automotive industry undergoing a period of change, why did you choose IPC?<\/h3>\n

For some time now, solder appearance standards have been perceived quite differently, even with similar content and conditions, depending on whether they are IPC-based, based on Toyota’s in-house production, or JIS. It was also significant that the IEC was also based on the IPC.<\/p>\n<\/div>\n<\/div>\n<\/div>\n

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What has been the reaction to the introduction of the IPC, both internally and externally, as well as from overseas offices?<\/h3>\n<\/div>\n
\nWe have created a new Toyota Technical Standard with IPC at its core and rolled it out internally, and now it is gradually being communicated and recognized outside of the company from there. Major suppliers have responded very positively to the idea of changing to Toyota Technical Standards (TS) in line with IPC standards, and TS can be disclosed to suppliers upon request. We have been able to get suppliers to understand the TS by looking at it.<\/p>\n<\/div>\n<\/div>\n<\/div>\n
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Aiming to Realize Soldering Durability and Efficient Quality Control with the New Technical Standards <\/h2>\n<\/div>\n
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What were the differences\/gaps between Toyota\u2019s quality requirements and IPC\u2019s requirements? <\/h3>\n

For example, in IPC requirements, solder balls are acceptable if they are entrapped, encapsulated, or attached. However, automobiles are expected to use for a prolonged period in various harsh environment such as extremely freezing weather and hot\/humid conditions. <\/p>\n

Even though those solder balls are entrapped, encapsulated, or attached in the coating material, the coating alone cannot guarantee the stability over the end of the vehicle\u2019s life. For covering and supporting those IPC requirements, we added supplemental description to Toyota\u2019s Technical Standards, such as what would happen if those entrapment, encapsulation, or attachment are loosen. In case that the standard just says \u201cAcceptable, if solder balls are fixed (entrapped\/encapsulated\/attached) at the initial stage of soldering process\u201d, then the idea will be resulted in obtaining a pass\/fail status by just making a checklist and marked or unmarked the items. To prevent this situation, we continue to communicate and discuss with our suppliers as usual, to achieve a product quality goal that must be guaranteed. <\/p>\n

In regard to this newly developed Quality Standards, what are you expecting from your domestic and overseas suppliers? <\/h3>\n

For global suppliers, Toyota requires its own standards, and other OEMs may require IPC standards. We believe that there was a troublesome tasks and efforts due to these two (2) different standards. By adopting IPC into Toyota in our TS, we hope all suppliers will be able to control their soldering quality efficiently.
\nIn addition, due to the once-in-a-century transformation in the automotive industry and efforts for CASE technologies, Toyota will be more likely to interact and deal with new suppliers than ever before. In such cases, by utilizing IPC as a Common Language, we expect that soldering quality control can be performed by both of we and supplier at an earlier stage and more efficiently. <\/p>\n<\/div>\n<\/div>\n<\/div>\n

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In new Era that Changes with CASE Technologies, Building New Relationships with Suppliers Utilizing IPC as a Common Language<\/h2>\n

There are still many companies in Japan that are unfamiliar with IPC. Would you please summarize today\u2019s discussion and give advice and messages for those companies? <\/h3>\n<\/div>\n
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When we deployed Toyota\u2019s internal standards\/criteria to suppliers, we were often asked about the relationship with IPC standards. We have been approved suppliers who manufactures semiconductors and\/or devices for automotive use. By adopting IPC this time, suppliers will be able to efficiently verify and assure their manufacturing quality at the global level. As a result, we hope to build a \u201cWin-win relationship\u201d with suppliers. <\/p>\n

Since we are in a period of once-in-a-century transformation and in the time of \u201cCASE\u201d, It would not be enough just to rely on the past knowledges and experiences. We would like to be a teammate of IPC\u2019s global network so that we will be able to implement various technologies on Toyota vehicles, while incorporating the latest information<\/p>\n<\/div>\n<\/div>\n<\/div>\n

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Download<\/div>\n
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To learn more, click here to download the PDF file.<\/p>\n

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Case Studies of IPC (Full Version)<\/a><\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n","protected":false},"featured_media":0,"template":"","casestudy_category":[249,257,290],"casestudy_tag":[277,275],"acf":[],"aioseo_notices":[],"_links":{"self":[{"href":"https:\/\/www.japanunix.com\/en\/wp-json\/wp\/v2\/casestudy\/11019"}],"collection":[{"href":"https:\/\/www.japanunix.com\/en\/wp-json\/wp\/v2\/casestudy"}],"about":[{"href":"https:\/\/www.japanunix.com\/en\/wp-json\/wp\/v2\/types\/casestudy"}],"wp:attachment":[{"href":"https:\/\/www.japanunix.com\/en\/wp-json\/wp\/v2\/media?parent=11019"}],"wp:term":[{"taxonomy":"casestudy_category","embeddable":true,"href":"https:\/\/www.japanunix.com\/en\/wp-json\/wp\/v2\/casestudy_category?post=11019"},{"taxonomy":"casestudy_tag","embeddable":true,"href":"https:\/\/www.japanunix.com\/en\/wp-json\/wp\/v2\/casestudy_tag?post=11019"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}