Vol.

14

TO YOTA

T E X T I L E

M A C H I N E R Y

B U L L E T I N

2 Special Feature
Introducing the RX240NEW-EST

4 Special Feature
JAT710: Toyota New Air Jet Loom

5 Topics
Toyota to Exhibit at CITME 2002

6 Customer Support & Service

A Look at Toyotas Global Service Centers Part 7: Wujiang Office, Shanghai Service Center (China)

A Message From the Service Department 7 Thoughts & Feelings

User Report Part 13: Thai Rung Textile Co., Ltd. (Thailand)

8 Toyota @ Work
Introducing Toyotas Businesses Part III: Vehicle Division

Introducing the

RX240NEW-EST
Features Toyotas Original Compact Yarn Spinning System
Toyota is proud to present the RX240NEW-EST, the latest ring spinning frame based on the highly acclaimed RX240NEW and equipped with a new compact yarn spinning system.

The RX240NEW-EST is equipped with Toyotas original compact yarn spinning system. The condensing device, consisting of a suction slit and perforated apron, provides smooth collection of fleece fibers and stable spinning of highly even yarn with low hairiness. A simple four-spindle structure ensures excellent operability and easy maintenance.

Stable Spinning of High-Quality Yarn

A condensing device, consisting of a suction slit and perforated apron, has been added onto the roller section to enable smooth collection of fleece fibers and improved fiber parallelization. By eliminating the spinning triangle, this device ensures stable spinning of high-quality yarn with low hairiness and improved evenness, greatly contributing to yarn strength and elongation.

Spinning triangle

Conventional yarn

Compact ring yarn

S P E C I A L

F E A T U R E

Main Features

Simple Structure

High Quality
I Smooth collection of fleece fibers thanks to a suction slit and perforated apron. I Precise slip-free rotation of the perforated apron thanks to positive drive of the top and bottom delivery rollers. I Inverter-controlled adjustable suction pressure.

The simple and rigid structural design concept of the RX240NEW has been applied to this compact yarn spinning system.

Suction Ducts (48 spindles per section)

Placing the suction ducts on the upper part of the roller stands results in a simplified design and shortened piping route.

Condensing Units
For easier handling, each 4-spindle condensing unit can be conveniently detached and disassembled without using special tools.

Delivery Rollers
Suction device The rollers are driven by a geared front-bottom roller and maintenance-free carrier gear, resulting in a simpler structure.

Excellent Operability
I Easily detachable condensing unit. I Perforated apron, driven by a bottom roller, is not affected by top roller diameter.

From the Designer

When developing this compact yarn spinning system, we had to keep in mind not only how to improve yarn quality but also how to increase operability and make maintenance easier. We gave the condensing unit an easy-to-handle, 4-spindle integrated structure so that it could be readily detached from the main unit and easily disassembled and reassembled during maintenance. We also designed it so that it could be fitted onto the currently available RX240NEW, turning it into a compact yarn spinning frame simply by adding and exchanging some parts. Well continue our commitment to developing better products by listening closely to customer requests.

Condensing unit

Flexibility
I Can be easily switched between compact and conventional spinning. I Available for retrofit onto the RX240NEW.

S P E C I A L

F E A T U R E

Toyota New Air Jet Loom

JAT710 (with E-Shed)

Since its introduction, the JAT610 has become the best-selling air jet loom in the industry, enjoying high acclaim from customers around the world. Now, as the world becomes more and more information-oriented, the needs of the customer are becoming more diverse and complex. With this in mind, Toyota has taken the JAT610 a step further and developed the new JAT710. The JAT710 has been designed under the same concept as the JAT610: weaving the highest quality fabric at the lowest possible cost, and boasts improved features such as higher speed, lower vibration and lower energy consumption. Plus its equipped with the latest electronics technology such as a new Internet-capable color function panel, taking todays weaving mill into a new dimension.

Less Vibration

30
DOWN

State-of-the-Art Electronics Technologies for Future Advanced Weaving Mills

State-of-the-art electronics technologies, including a new color function panel and a high-speed CPU offer greatly enhanced communication capabilities for advanced weaving mills.

Machine vibration is reduced through further improvements over the JAT610 in frame structure and beating motion.

New faster CPU and color function panel

New color function panel

(32-bit/266MHz CPU)

New beating mechanism

Internet

Ethernet LAN

Electric drum pooling

Main computer
(32-bit/133MHz CPU)

Less Air Consumption

20
DOWN
Electronic let-off motion
(16-bit CPU)

Fiber-optic communication

Electronic leno device

New technology offers further savings in air consumption over the JAT610 which is already well received due to its low air consumption.

Electronic take-up motion

MAX
High Speed

Electronic shedding
(32-bit CPU)

1250rpm
*R/S 190 cm

Extended Versatility
Extensive options greatly increase the range of versatility.

A maximum operational speed of 1,250 rpm* is now possible due to numerous improvements such as a new weft insertion system, new frame structure and higher CPU processing speed.

Note: Figures based on Toyota tests.

TOPICS

Toyota to Exhibit at CITME 2002

Toyota Industries will participate in the 8th China International Textile Machine Exhibition (CITME 2002), Chinas largest textile machinery show, to be held October 15 (Tuesday) to 19 (Saturday) at the China International Exhibition Center in Beijing. Toyota will introduce its latest technologies, including demonstrations of five of its most advanced looms, at booth No. 3B01 on the 1st floor of Hall 3.

Products Exhibited
G G G G Three JAT610 air jet looms One JAT710 air jet loom One LW600 water jet loom One RX240NEW-EST ring spinning frame with compact yarn spinning system (partial unit)

In the five years since its introduction, the JAT610 has captured and held the industrys top market share. We have enhanced its versatility by integrating a host of newly developed systems such as electronic shedding and a weft insertion device for yarns of different types and counts. We will demonstrate high-speed weaving of fabrics that require such advanced technology. We feel the JAT610 will prove to be the worlds most reliable. We will also exhibit the new JAT710 in China for the first time. Visitors to the Toyota booth will be able to see its newly designed weft insertion system, which reduces air consumption by approx. 20%, and its high-speed, lowvibration operation (vibration reduced by approx. 30%) thanks to a new frame structure and beating mechanism. The JAT710 boasts the latest electronics technology including a new Internet-ready color function panel.
At the CITME 2000 show

A demonstration of the LW600 water jet loom equipped with BLD (blowerless drum) measuring will give visitors a firsthand look at its capability to weave high-density industrial materials at high speed and low cost. Well introduce our spinning machinery too, with a presentation of the new RX240NEW-EST ring spinning frame (partial unit) equipped with Toyotas originally developed compact yarn spinning mechanism. Please be sure to visit the Toyota booth and see for yourself Toyotas advanced technologies. We are looking forward to your visit.

Visitors check out the latest from Toyota at CITME 2000

C USTOMER S UPPORT
Part 7: China
Shanghai Service Center

&

S ERVICE
Toyota has established 11 service centers around the world to supply spare parts and provide aftersales service, and is developing a system to respond more quickly to customer needs. In this section of each issue, we will introduce one of these service centers. This issue, we take a look at the Shanghai Service Centers Wujiang Office.

A Look at Toyota's Global Service Centers

Wujiang Office
Sheng Xi He Qiao Dong, Nan Huan Road, Sheng Zhen Town, Wujiang City, Jiangshu Sheng, China Tel: +86-512-63569608 Fax: +86-512-63563517

Wujiang, Jiangsu

The Wujiang Office of the Shanghai Service Center was established in June 2002 in the city of Wujiang in Jiangsu Province. This makes it the third service base in China after Shanghai and Shaoxing. The Shanghai Service Center, with its easily accessible and convenient location, is in charge of such matters as installation supervision, after-sales service and parts sales across the country. The Wujiang Office, on the other hand, is aiming to be a service center close to the local area. Its located in an area where many of our customers have their mills so they can easily visit our office. Presently, Wujiang is aiming to be one of Chinas biggest textile industry centers, producing high value-added fabrics. Many companies are reinforcing their plants and equipment and pushing forward with technical innovation, and Toyotas air jet looms are at work at many of these mills. We expect to sell more air jet looms, water jet looms and preparatory machines, making the role of the Wujiang Office more important. The Wujiang Office currently has 5 full-time employees with help from some of the staff of the Shanghai Service Center. Together they promptly handle customer enquiries and offer full service including giving advice on installing textile machinery and after-sales service for Wujiang and the surrounding areas.

Wujiang Office, Shanghai Service Center

Everyday is a Challenge!
Service Manager

Installation and After-Sales Service Engineer

Sun Xiao
After graduating from textile college, I worked as a designer at a textile machinery manufacturer. I joined Toyotas Shanghai Service Center in 1999. Currently, as manager of the Shanghai Service Center, I am also responsible for the Shaoxing and Wujiang Offices. Its been challenging to keep up with the advances in technology. This year in particular, a few thousand air jet looms were installed in the Wujiang area, making our jobs more challenging. The service centers main responsibilities are loom installation and adjustment, after-sales service, spare parts supply and repair. In the future, we hope to expand our business range to include technical training for our customers.

Wang Shu Sheng

I joined the Shanghai Service Center four years ago and have since installed mainly air jet looms across the country and provided after-sales service. I came to the Wujiang Office upon its establishment. I still have a lot to learn compared to my Japanese colleagues, but four years of experience has given me confidence in my skills. Once a month, the Japanese engineers in Shanghai hold a technical training meeting, and I take the opportunity to raise my skills by asking questions whenever I attend these meetings and whenever I accompany Japanese engineers on visits to customers mills. I am well aware that improving our skills leads to higher customer satisfaction and will continue my efforts.

A Message From the Service Department

Mitsuhiro Iwasaki, Service Department Manager

First of all, thank you very much for your continued patronage of Toyota textile machinery. It is much appreciated. Maintenance is an important aspect of ensuring consistent quality and long-term reliability. Here, we would like to bring to your attention a few important maintenance items identified by our service technicians in the course of after-sales service. While these items are extremely basic, if neglected, they could become the source of serious problems.

Air Jet Looms

1. Proper preparation of the installation location and correct equipment set-up are the two most important factors in ensuring the safe long-term use of looms with consistently high performance. Follow the instruction manual carefully, especially in regard to foundation work for the floor, electrical grounding connections, and the air supply system. 2. To ensure the reliability of components and maintain excellent fabric quality, be sure to lubricate the beating section and the let-off on a regular basis. 3. To achieve stable weft insertion, we encourage you to periodically clean the reed. Allowing oil solutions or sizing materials to build up in the reed dents will severely degrade the consistency of weft insertions.

Water Jet Looms

1. Shedding connecting rods in the crank shedding mechanism should be lubricated each time the looms beams become empty (every 10 days). This section is subject to a great deal of water influx, and regular lubrication is important to maintain adequate levels of grease on friction surfaces. 2. It is important to check carefully for overstretched motor drive belts. Press on the belt to check whether the belt bows adequately. Overstretching will not only reduce the service life of the belts, but also shorten the service life of motor bearings.

Spinning Machinery
1. It is important that foundations be designed and built to provide adequate floor loading capacity. This is critically important in maintaining a flat floor surface over the long term. Also, because even a tiny eccentricity in rollers will have an impact on yarn quality, it is important to check the levelness of the machinery itself. 2. To maintain consistent yarn quality, the recommended change interval for spindle oil is 4,000 hours. 3. To bring the spinning machinery to a smooth stop, it is important to adjust the main brake gap. Be sure to make checking the gap a regular maintenance item.

T H O U G H T S & F E E L I N G S USER REPORT

Thailand
Bangkok

Part 13

Thailand

Thai Rung Textile Co., Ltd.

Thai Rung Textile Co., Ltd. (TRT), the core of the TTI Group, is located near Bangkok. Based on the slogan Achieve world standard and maintain it, the company has purchased Toyota machines every year for the past several years. TRT currently has 38,000 spindles of Toyota ring spinning frames, led by the 21,600 spindles of RX240NEWs that it installed in 2001. These machines spin T/C Ne45 yarn at an average machine speed of 20,000 rpm, among the fastest speeds in the world. We spoke with the companys managing director Mr. Mongkol Mangkornkanok about how Toyota helps his business.

TRTs Motto

Achieve World Standard and Maintain It

Give us your thoughts on Toyota machinery.
We first started using Toyota RY4 ring spinning frames in 1985. The next year, we began using FL16 roving frames, and in 1995 we purchased some RX220 ring spinning frames. All of these machines are still in fine condition and operating today. Although we had some other companies machines, we decided to replace them with Toyota machines. In 2001, we simultaneously installed 21,600 spindles of RX240NEW ring Managing Director spinning frames along with FL100 Mangkornkanok roving frames, DX7A drawing frames, and VC5 combers so we could spin polyester and cotton blended yarns. With an average machine speed of 20,000 rpm, high yarn quality and productivity, ease of maintenance, and durability of parts, we are very satisfied. In short, choosing Toyota machines was the right decision.

RX240NEW ring spinning frames at work

Do you have any requests for Toyota?

Electricity costs are continuing to increase. Because the cost of electricity accounts for 35% of spinning yarn, we would like to see Toyota put more effort into developing machines that consume less power. Also, because we must meet customer needs for varying yarn counts, we would like to see Toyota develop a system for fast and easy ring changes on any kind of ring spinning frame.

How has Toyotas after-sales service been?

So far, we are satisfied with Toyota machines and after-sales service. In fact, we are very pleased with the way Toyota has promptly dealt with all matters, no matter how small, during everything from machine installation to start of operation.

T O Y O T A

W O R K

Introducing Toyotas Businesses

Part III

Vehicle Division

In Part III of Toyotas company introduction, well introduce you to our vehicle division, which is a very important foundation of our entire business. Our consolidated net sales for fiscal 2001 was 980.1 billion yen, and the vehicle division made up approximately 30% of this amount.

History of the Vehicle Division

1967 Nagakusa Plant starts operations producing compact cars. 1978 Begins production of the Starlet. 1987 Begins production of the Corolla Liftback. 1999 Begins production of the Vitz (Yaris). 2001 Begins production of the RAV4 and the bB Open Deck.
(Billion yen)

Sales

The vehicle division currently manufactures automobiles such as the Vitz (Yaris in Europe), the RAV4 and the bB Open Deck. Using the latest production facilities and the Toyota Production System, we manufacture automobiles through a consistent production system that encompasses everything from design, press and welding to painting, assembly and inspection. Our strict quality control also contributes to producing automobiles trusted by customers around the world. Toyota is constantly pursuing the ultimate balance of function, performance and cost in its compact cars, based on users point of view. For example, we took part in the development of the bB Open Deck from the initial stages of planning and design. We are also actively involved in creating concept cars that offer next-generation driving pleasure.

200

Recent Developments
150

Deck: bB Openmaking The Toyota Groups first car to be developed without a prototype. We handled everything from planning and design to production. Its a totally new car that offers the ultimate in fun and freedom. sense refinement not found in Premio/Arion: AOfferingofvarious seat arrangementsother cars of the same class. not available with conventional sedans, these cars provide greater comfort and enjoyment.
, , , , , , , , , , 91 92 93 94 95 96 97 98 99 00

100

50

the best performance of compact car ist: Featuringdesign both inside and in this classoffers its drivers and a classy out, the ist a feeling of refined elegance.

Main Products
RAV4

The RAV4 looks good and handles well not only on rough roads but also on busy city streets. Its compact but is roomy enough for comfortable driving. Equipped with a D-4 direct-injection engine, the RAV4 also gives consideration to the environment by reducing the amount of CO2 emission.

Vitz (Yaris)

The Vitz has a sophisticated design fusing functionality and style. Although compact, the interior is roomy enough to comfortably seat four adults. Featuring the best fuel economy ratings in its class, the Vitz (Yaris) is also environmentally friendly. Standard equipped with safety features such as ABS, break assist and SRS dual airbags, this car offers the worlds highest level of safety in its class as well.

bB Open Deck

A new breed of compact car, the bB Open Deck is ideal for the active young driver. It has an open space in the back like a pickup truck and a wide, easy-access door, which can be used for a wide range of uses such as carrying bulky cargo for outdoor leisure.

About the Cover: Traditional Japanese Paper Dolls

2-1, Toyoda-cho, Kariya-shi, Aichi 448-8671, Japan Tel: 81-566-27-5326 Fax: 81-566-27-5307 URL: http://www.toyota-industries.com/textile/ E-mail: kaoru.kondo.aa@mail.toyota-shokki.co.jp Please send your comments or questions regarding the Toyota Textile Machinery Bulletin to any of the above addresses. Contact person: Ms. Kaoru Kondo Art direction and editorial assistance: Cs Inc. Printing: Okamura Printing Industries Co., Ltd.
Paper doll making is one of the traditional Japanese crafts. Despite the dolls blank faces, their overall appearance speaks of the elegance and grace that typifies the ideal Japanese woman and evokes the unbridled charm of Japan in the good old days. Because the paper dolls are light yet sturdy, they make popular gifts from Japanese people travelling overseas.

TOYOTA TEXTILE MACHINERY BULLETIN Vol.14

Published September 2002 All rights reserved. Reproduction in whole or in part without written permission is prohibited. This bulletin is printed on recycled paper.
Printed in Japan