Maintenance at Toyota, a key contributor to factory performance

Interview of Reynald Debaut-Henocque, ex-Vice-president of Manufacturing at Toyota Motor Manufacturing France


Maintenance is a hot topic at Toyota when it comes to increase productivity: at the Onnaing factory producing the Yaris model in the north of France, Toyota Motor Manufacturing France (TMMF) envisions going from a production of 3 millions of Yaris copies in twenty years time to a production of the same volume but in only ten years time. Doubling the productivity this way cannot happen without a flawless maintenance.


When TMMF started to implement 3-shifts a day in its factory, the company already had to revise its maintenance approach to reach an unprecedented requirement level. To guarantee an uninterrupted production flow during weekdays, maintenance, both curative and preventive, which could take place only during weekends, must be impeccable. Equipment backup methods have also been deployed to react if breakdowns occur.


To achieve such high expectations in maintenance at TMMF:

- standards and working conditions of the maintenance staff are common areas of focus of continuous improvement,

- maintenance are consistently enticed to train themselves and to development their competencies internally,

- no maintenance is outsourced (except when heavy equipment suppliers need to be involved)

- equipment are regularly revised to become more and more easily accessible and changeable.


The availability rate of the machines is higher than 95% overall in Onnaing.



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Marris Consulting, expert in Theory of Constraints & Critical Chain Project Management


Marris Consulting is an expert in the Theory of Constraints (ToC) and Critical Chain Project Management (CCPM). As industry consultants, we are focused on helping process and manufacturing industries reach their highest levels of performance by using Constraints Management  combined with Lean and Six Sigma. We also use Critical Chain Project Management which we sometimes combine with Lean engineering to improve project performance. If you are unsure about the actions which need to be implemented to improve operational efficiency, our industrial management consultants can also conduct a performance audit. Furthermore, our experts host numerous Theory of Constraints (ToC), lean and project management training sessions throughout the year.

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About Marris Consulting

Marris Consulting is an industry consulting and training company specialized in the Theory of Constraints (ToC) and Critical Chain Project Management. We focus on improving the performance of manufacturing and process industries by using Constraints Management combined with Lean and Six Sigma. To boost project performance, we also use Critical Chain Project Management (CCPM), which we sometimes combine with Lean Engineering. Our 2-day performance audits, our performance consulting services and our project management, Lean, ToC & CCPM training by our industry consultants offer a wide range of solutions to help our clients around the world reach the highest possible levels of performance.

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