Toyota discloses unprecedented details of F1 development

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January 23, 2006 There are just two environments akin to the acute excellence required to compete successfully at Formula One level – a space launch and the battlefield. All three areas are so close to the edge of human understanding that the technology developed in their pursuit often filters down to consumer products and introduces a better way. Panasonic Toyota Racing officially kicked off its 2006 Formula 1 campaign with a special event at the Toyota manufacturing facility in Valenciennes, France earlier this month, at the same time as disclosing an unprecedented amount of information about the Toyota production process and how it has been applied to the former art, and now decidedly scientific process of Formula One. Incredibly, the company has applied knowledge developed in manufacturing production cars to improve its Formula One competitiveness . If you’re into car racing or manufacturing, this is a “must” read!

Panasonic Toyota Racing has adopted a unique approach to its 2006 racing season and chose to veer away from the more established ‘car launch’ as its TF 06 race car has already completed substantial test mileage since its inaugural run at the Circuit de Catalunya in Barcelona on 29 November last year. A huge effort by the entire team to ready the new car in record time resulted in that unprecedented early rollout, which formed a key part of the team’s push for success in 2006, a year that sees special challenges as the entire field adopt new V8 engines and Toyota joins forces with its new tyre partner, Bridgestone. Toyota’s aggressive development programme is a clear sign of its intentions in Formula 1. Having introduced the podium and pole-scoring TF 05B for the final two races of 2005, the TF 06 hit the track just six weeks later, stunning rival teams. Read on for an extensive article covering in depth the development process of the Toyota TF 06.

“We feel that the concept of holding a new car launch at the beginning of each year, just for the sake of it, is outdated,” explains Technical Director Chassis Mike Gascoyne. “We are updating more major elements on an increasingly frequent basis. Although this can be a difficult process to manage it does mean that we can ensure resources are being spent in areas that make the car go quicker, as and when it is required, and not simply on redesigning existing components just because we feel that we have to. Consequently, we have moved to a process of continuous evolution, hence the smooth transition from TF 05 to TF 05B and to the early completion of TF 06.”

That ongoing process will continue with the introduction of the TF 06B – currently scheduled for the seventh race of 2006, the Monaco GP. The policy of continuous improvement reflects the philosophy of kaizen, a key element of the Toyota Way, the set of principles that guides the company at every level, even within its Formula 1 programme!

Work at Toyota Motorsport’s Cologne-based factory is increasingly benefiting from the use of Toyota Way thinking, and in particular the Toyota Production System (TPS) techniques that it encompasses. TPS has been used to improve efficiency in departments such as composites and engine production, helping to speed up the introduction of new developments.

“Toyota Production System is part of the Toyota Way and enables us to increase efficiency in all areas of the corporation by eliminating waste through a continuous improvement approach,” comments Chairman of Toyota Motorsport and Team Principal of Panasonic Toyota Racing Tsutomu Tomita. “TPS has been expanded to all areas of the Toyota Corporation, including Toyota Motorsport and our Formula 1 activities.”

“Every day we can see and feel the benefits that TPS brings us,” adds President John Howett. “We have created a special TPS group in Cologne and by infusing TPS throughout the factory we have been able to cut down lead times, reduce costs, increase overall efficiency and positively impact all areas of the team with notable examples in CNC and Composites. It is an ongoing process, one which we encourage all team members to live by and embrace. There is no end to the improvement cycle and one major part of TPS is to promote the active involvement and feedback of the individuals doing the job, rather than simply dictate from above.”

The implementation of TPS has played a significant factor in the team’s ability to introduce the TF 06 early. The intention was to get as much experience as early as possible with both the V8 and Bridgestone tyres as part of a definitive package, rather than with an adapted 2005 car.

Technical Director Engine Luca Marmorini explained: “With the move from V10 to V8 engines in 2006, it has been extremely beneficial to have the TF 06 package running in the November-December tests. By waiting until January, it would be too long to react and change long-lead parts in time for the first race. We were able to confirm things that we tested on the dyno and generally we have maximised our time. All drivers have given us positive feedback in terms of performance and reliability, so we were already confident that we had a raceable package, even if the rate of development never stops.”

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