Look forward to a [606362]

Look forward to a
Brighter Future with
Blue Arrow & T oyota
Information Booklet
Delivering Recruitment Solutions.

Look forward to a Brighter Future with Blue Arrow & T oyota
Blue Arrow & Toyota
Y ou’ve just made your first step on what we hope will be a long and exciting journey with Blue Arrow and T oyota.
The recruitment process and the job will be extremely demanding so don’t expect the journey ahead to be easy. However,
the Blue Arrow team will be with you at every stage to provide valuable feedback and support.
Perhaps more importantly, we offer a package which combines a great salary with professional development and long term
career opportunities.
Permanent Contract with monthly pay
Basic salary of £18,602 + Overtime + Shift Pay
25 Days Holiday a year
Career development – TMUK
Apprenticeship Framework
Subsidised staff canteen
Uniform
Introduction to Blue Arrow
Blue Arrow has been recruiting production operatives to
work alongside T oyota’s permanent work force at Burnaston,
Derby since January 2001. Here, you will have the opportunity
to play an essential role in the manufacturing of the Avensis
and Auris, using the T oyota Production System (TPS) which
has set new standards in manufacturing excellence.Since 2001, over 2000 Blue Arrow workers have been
transferred to permanent contracts with T oyota Manufacturing
UK. It is our ongoing commitment to you to continue to
invest in the welfare of our workers and to provide you with
a professional service in an open and honest manner.
Blue Arrow Permanent Contracts
From 2010 all Blue Arrow Members on site have been placed on permanent contracts. Y ou now receive
the same salary as a TMUK new production team member of £18,602 + OT and Shift Pay.
The Recruitment Process
If you have received this pack you will already have
passed through the first part of the recruitment
process (the call centre pre-screen) and should be
booked onto the first on-site testing session. This will
be a 3 hours computer based assessment and you
will be told on the day whether or not you have
been successful.
The second on-site test is a physical test and is call
the Day at Work Assessment. This test is designed to give you firsthand experience of what it is like to work at T oyota. Y ou
will be tested on following standardised work, accuracy, work
pace and dexterity. Y ou should think of this as a 2 way test; for
you to see if the job is right for you and for us to see if you’re
right for the job.
The final stage of the process is a one-to-one
interview which is your opportunity to tell us why
you’re the right person for a job with Blue Arrow
at T oyota.
Delivering Recruitment Solutions.This booklet will give you information about
the recruitment process which you need to
pass through in order to become a Production
Team Member, and information on what to
expect when you start your career with Blue
Arrow at Toyota.

Look forward to a Brighter Future with Blue Arrow & T oyota
Toyota & You
T oyota Motor Manufacturing (UK) Ltd began producing cars in
1992 with the introduction of the Carina E and the subsequent
introduction of Corolla in 2001. In June 2010, Burnaston
produced its 3 millionth vehicle and, today, we currently
produce the Avensis, the Auris which was launched in February
2007 and the Auris HSD which was launched in June 2010.
In total, T oyota has invested in excess of £1.85 billion
and we currently have a capacity to manufacture
around 285,000 cars each year. T oyota has also invested
in their Deeside Engine Plant in North Wales where,
in February of 2007, the 3 millionth engine was manufactured. T oyota is committed to producing high quality cars at a
reasonable price to satisfy the needs of our customers. This
commitment forms the basis of a partnership between
T oyota and its members as they believe that their people are
the key element to the success of the Company. T oyota brings
to the partnership state-of-the-art manufacturing technology
and management practice. Y ou bring energy, enthusiasm, a
commitment to hard work, creativity, knowledge and your
resourcefulness. T oyota does ask a great deal of its Members
but they give a great deal too.
Teamwork at Toyota
T oyota is not just hiring “workers”, we are hiring T eam
Members who will work together to accomplish tasks or a
series of tasks. Every Member needs to be open to new ideas
and challenges every day. Y ou will be encouraged to listen,
learn and understand not only your own, but other Members’
jobs as well; to show patience; to express ideas. At T oyota we
all need to adapt to rapidly changing conditions, and to work
with or, on occasion, substitute for our colleagues.
T oyota believes that teamwork is an essential part of the
workplace. T oyota has created a positive team spirit in the Company; as everyone knows that everything they do
affects many other people. Company success is necessary for
security and long term prosperity for all Members.
Quality is another key factor at T oyota and goes hand in
hand with teamwork. High quality standards start with every
Member. All Members are expected to take part in quality
discussions and to meet together to discuss ideas. It is every
Member’s responsibility to correctly complete their job and
only to pass on 100% quality work to the following process.
What Toyota is like?
T oyota do require a great deal from their Members
and in the true spirit of trust, they want all potential
Members to understand what working at T oyota will
be like.
Firstly, working at T oyota will be demanding. Y ou will receive
full training in all jobs and tasks you are asked to do, and you
will learn a standard way to carry out your duties. T oyota
places great emphasis on standardised work as it leads to
quick mastery of the job, minimises problems due to lack of
experience and ensures high quality and safety.At T oyota, we place a great deal of importance and emphasis
on good timekeeping and attendance. All our Members
are key to the success of the Company, and everyone
who is recruited is critical to the effective achievement of
our production targets. Indeed, Members tend to arrive
before start time so they can prepare for their working day.
This means that our operation is “lean” in people terms.
If you believe you have the commitment to give T oyota
your best efforts and attendance, we in turn will offer you
a challenging job opportunity.
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In summary, the T oyota working environment has the
following main elements:
Hard, demanding work e.g. standing and active for the
majority of the day
Repetitive work, e.g. performing the same task over
again for a full shift
Shift work
Overtime when required (mandatory)
Good attendance and punctuality is essential
Nature of the work
Fast paced Production Environment
T argets will be given for each shift, and there is normally
a set amount of time allocated to complete your process.
For example, in Assembly 1, the ‘Optimum speed’ for the
Assembly line is 66 seconds. This means that if each process
is completed in this time, a car can potentially come off the
assembly line every 66 seconds.
Repetitive Process
The training period for any one process can take up to 4
weeks, therefore you could be expected to perform this
process for a whole shift, at least 5 days a week. Within
your first 12 weeks service, you may be trained to perform
between 1 or 2 processes, depending on what part of the
plant you are assigned to.
Hard Work
Due to the repetitive nature of the job, it takes a lot of
dedication and hard work to keep up to speed with targets,
whilst remaining vigilant with quality issues. Y our job can also
be physically demanding. T o assist in the moving of heavy
parts, hydraulic lifting equipment can be found across the
plant. For example, in the Weld shop, panels are attached to
the body shell with the aid of a hydraulic frame. Long hours
Overtime at T oyota is mandatory, which can involve working
up to (or even in excess of) 2 hours extra per shift. However,
T oyota reserve the right to increase the overtime, (within the
‘Working Time Regulations’), dependant on business needs.
Stood on your feet all day
It is important that you attend every pre-shift meeting to
make sure that you are involved in the warm-up exercises.
Apart from your break times, you will probably be on your
feet for your whole shift.
Attendance / Punctuality
As you will be working as part of a team, you will be expected
to maintain a good attendance record. It is vital that you
contact the office and your group leader if you are unable to
attend work, at least 30mins before the start of your shift. Do
not forget that any non-attendance will be unpaid and will
impact on your chance of progressing to a TMUK contract.
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Continuous Training and Development
As accredited ‘Investors in People’, both Blue Arrow and
T oyota will ensure you are provided with professional
training. Y our personal development within the job-role will
be monitored on an individual basis, and will contribute to
your appraisals with your Group Leaders. An appraisal is a
reflection on your own personal merit, covering items such
as attendance, attitude and the quality of your work.The first 4-5 weeks at T oyota is the most critical time to
develop your skills whilst being trained. It is therefore very
important that you do not take any holidays or have any
unnecessary absence during this time.
Training periods may vary throughout the factory. Y ou will
also have ongoing training throughout your career at T oyota
to develop new skills.
Production Areas – Possible Placements
Working at T oyota can be hard work, but if you are an
innovative, quality conscious team player, you will find T oyota
very rewarding.It is important that you are flexible to the process that you
are given and also the shift on which you are placed, as you
could be placed in any one of a number of areas. This decision
is made based on the recruitment process and is subject to
T oyota business needs.
Press and Weld
At the forefront of the whole ‘T oyota Production System’
are the Press and Weld shops, which are linked very closely
with each other due to the vast amount of parts needed to
manufacture the Avensis and Auris.
At its optimum speed, a car can come off the end of the line
every 66 seconds at T oyota, therefore the speed at which the
Press shop operate can have a knock-on affect on the whole
plant. It is therefore essential that the job has got to be “right
first time”.
A car will start as a huge roll of steel. In the Press shop, these
raw materials are transformed into car parts by huge industrial
press machines. Working in this area requires a lot of loading/
unloading of parts on and off machines, with the assistance of
robotic hydraulic arms. The press machines are programmed to
cut parts to a certain specification for either the Avensis or Auris.T o ensure the smooth running of all shops the 4 ‘S’ system
is very important. This ensures that the work areas are left
‘SORTED’, ‘SIFTED’, ‘SWEPT’ and ‘SPICK and SPAN’, making
the work area safe and tidy. In shops such as Press and Weld
where the environment is particularly fast moving, vigilance
towards the 4 ‘S’ system is extremely important so that one
shift can run straight into the next.
Parts produced by the Press shop are passed straight to
the Weld shop, which re-enforce those parts with steel and
construct the Avensis or Auris body shell.
There are a wide variety of jobs that a candidate could be
assigned to within the Weld shop. Some potential areas
include; Under Front and Under Rear, Shell body, Quality
Assurance and Conveyance.
Paint
An operative going into the Paint shop may be placed onto any of the following processes:
‘ED’ (Electro deposit), this is where the paint is charged
with electricity to attract to the car body shell, giving the
car its first coat of paint. ‘Anti-chip robots’, these treat all of the car body except
underneath, to prevent against erosion.
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Sealer’, this is where the window and doorframes
are made watertight. The car bodies then go
back to ED to be baked off and the under body
is sealed and prepared for ‘Primer’.
In ‘Primer’ robotic arms give the car its main coat of
paint and underneath the car body is hand sprayed. The
cars are then given an off-line inspection to identify any
faults.
The next process is ‘T op Coat’ where the
doorframes and windows are masked with tape
before the base coat of colour is applied, ready
to be oven dried off. The ‘Quality Division’ from Weld operate in
the paint shop checking and inspecting after the ‘T op
Coat’ is put on. The car body shell is then oven baked.
In ‘Finish’, the masking tape is taken off the door and
window frames and on-line polishers make quality
checks.
Last inspection is given to the cars in the ‘Colour Bank’.
This is where the car bodies are stored and then waxed
before heading into Assembly 1.
Plastics
The Plastics shop has three main areas, including;
Injection Moulding – which moulds plastic granules into
bumpers and instrument panels. Bumper Paint – which paints the bumpers and adds grills,
badges and fog lights.
Monofoam – which is related to producing the
IP (Instrument Panel).
Quality Assurance
T oyota operates a policy of ‘Right First Time’, which means
that quality is built into each part of the T oyota Production
System (TPS). Quality control is the responsibility of everyone. In all shops,
quality checks are made on both the Avensis and Auris.
Quality is of the utmost importance at T oyota. In many cases
this work involves checking the vehicles and vehicle parts at
the end of the production line.
Assembly 1
Members could be assigned to any of the vast amount of processes within the shop. Some examples include:
Trim 1
When the car body shells come over from the ‘Paint Shop’
the cars are sent straight to Trim 1 where the doors are taken
off to enable the operatives to get in and out of the vehicle
to fit the specified parts.
Trim 2
In Trim 2, the car heater is put in and the brake and clutch
pedals are fixed into place.Trim 3
In Trim 3, the Interior instrument panel (IP) is fitted.
Doorline
The doorline section is set aside from the production line as
a whole, as this process may start after Trim 3, but continues
throughout the rest of the process until the car is fully
assembled. In this process, the bare case of the doors are
fitted with window frames and mirrors. The interior trim for
the door is also added along with the door handles. Finally
the glass is fitted.
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Chassis 1
Most of the work in this section is underneath the vehicle so the
operative is often standing up fitting the brake and fuel pipes.
Chassis 2
In Chassis 2, the engine and gearbox are fitted along with the
front and rear suspension, ready for Engine Line.
Engine Line
This work involves members standing up for most of the
process and operatives often handle heavy components
such as starter motors. The engines are received
at regular intervals, supplied by T oyota Deeside in
North Wales.Chassis 3
Chassis 3 is predominantly trim related, fitting items such
as exhausts, carpets and bumpers along with the brake and
clutch fluids.
Final 1,2
These teams fit the front and rear windscreens, seatbelts and
part’s of the interior trim. They also fit the air conditioning
system to cars (depending on the car’s specification) and the
front and rear seats, ready for inspection.
The efficient operation of all departments depends on
close working relationships with both the Internal Logistics
Department and Quality Assurance.
Internal Logistics (Conveyance)
The Internal Logistics function operates with the primary
objective of supplying the production lines with the parts
necessary to build the vehicles. An operative assigned to ILD
will be assigned to drive either a Forklift truck or ‘Dolly truck’
and will work on the 2-shift rotating pattern in any shop.
Working ‘Just in Time’ means that parts are ordered and
arrive at the plant only when they are needed. T oyota do not
stock-pile parts, meaning that normally there is only one shifts worth of parts on site. A ‘Kanban’ system is used for each
part or number of small parts in each shop to monitor its
stock levels at minimum and maximum numbers.
When an operative on line has taken a part or parts for their
process, the ’Kanban’ for that part is sent back to ILD. They will
then replenish and re-order that stock. Fork Lift Truck operators
would then deliver those parts to the production line.
Hours of Work
The following shift patterns operate across the site.
Whichever job you are assigned to will dictate the shift pattern you will be on.
Shift Patterns
2 Week rotating shift pattern (2 weeks of each)
Days Mon – Fri 0730 – 1548
Nights Mon – Thurs 2030 – 0438
Fri 1830 – 0248
There is also MANDATORY OVERTIME OF UP TO 2 HRS in the
majority of areas on-site. Certain areas, however, may require
in EXCESS of 2hrs depending on the current workload. Y ou
will be told by the last break of the day how much overtime
there will be.You may also be required to work compulsory
production Saturdays (more notice will be given
for these).
Standard hours of work per shift (before overtime) 7.8hrs
Standard hours of work per week (before overtime) 39hrs
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Tea/lunch breaks
2 shift rotating pattern. 15 minutes first break
30 minutes lunch/night time meal
10 minutes second break
If you are required to work 2 hours of overtime or more, you will receive a further 15 minutes break.
Pay Rates
Salaried Pay
During your first of week of training you will not receive any
shift allowance and will only be paid at the ‘standard day’ rate.
Y ou will be paid on the last Friday of every month directly
into your bank account. If you start after the last Friday of the
month any money owed will be paid the following month.Y ou will be paid an annual salary of £18,602 which is broken
down in to 12 monthly payments of £1550.16. Overtime and
shift pay are paid the following month.
E.g. If you start work on January 1st on the last Friday in January
you will receive your basic salary of £1550.16, in February you
will then receive your basic salary of £1550.16 and your shift pay
and overtime for January.
Hourly Rate
Standard Day £9.15 per hr based on a 7.8 shift
Overtime 1 £12.20 per hour for first 2 hours
Overtime 2 £13.73 per hour for over 2 hours
Saturday £13.73 per hour all hours on Sat
Sunday/Bank Hols £18.30 per hour all hours Sun/BH
Public Bank Holidays
If you do not work on a Bank Holiday, you will just be paid at the ‘standard day’ rate for a standard day shift of 7.8 hrs as long
as you have worked a full week prior to and after the Bank Holliday. However, if you are required to work on a Bank Holiday,
you will also be paid at the Bank Holiday rate, for every hour worked.
Paid Bank Holidays
News Y ears Day, Good Friday, Easter Monday, May Day, Spring Bank Holiday, Summer bank Holiday, Christmas Day
and Boxing Day.
Shift Allowances
2 Week rotating shift patterns:
Rate
Days: £0.46 per hour
Nights: £2.75 per hour
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Delivering Recruitment Solutions.Workwear and Lockers
Y ou will be provided with workwear including 2 pairs of
trousers, 5 T shirts, and 1 sweatshirt, and also a locker for
your personal belongings. A £60 refundable deposit will be
deducted from your first 2 month’s wages (£30 per month),
to cover the cost of the uniform and locker key. This money
may be refundable if members leave Blue Arrow or are taken
on a permanent basis with T oyota.
T oyota is a cash free environment. Therefore you will be
issued with a vending card / security pass to purchase food,
drinks and snacks from the 3 subsidised canteens or vending
machines. Y ou can top-up your vending cards with credit on
site at the various card machines.All personal belongings including cash, keys and other such
metal objects MUST NOT BE TAKEN ONTO THE SHOP
FLOOR UNDER ANY CIRCUMSTANCES. These items can
cause damage to vehicles and have a significant impact on the
quality of the vehicle. This is one of the reasons for the issue
of vending cards to every member.
It can take up to two weeks to replace a vending card therefore
it is very important that you treat your card like cash and don’t
lose it.
Holidays
Your Holiday Entitlement
In a full year from January 1st – December 31st you have
a personal entitlement of up to 25 days holiday, which are
accrued on a pro rata basis of 0.48 days for every weeks
service.
The majority of your holiday entitlement must be saved to
cover the summer and winter shutdown periods. There is
no production at these times; therefore 14 days out of your personal holidays must be reserved to cover this.
Y ou will need 10 days to cover the first shutdown which
falls over the first two weeks of August, and 4 days for the
Christmas shutdown, leaving you with up to 11 floating days.
If you have holidays in excess of 7 days booked outside of
the shutdown periods you will need to speak to a member
of the team.
Absence Procedures
For any non-attendance there is an absence procedure that you
must follow:
Absence Reporting Procedure
Working on-site for Blue Arrow at T oyota UK you will be working
as part of a team in a lean manned environment.
This means that attendance and timekeeping are essential.
If you are unable to attend work for any reason there is
a reporting procedure that you must follow:CONTACT
GROUP LEADERCONTACT BLUE
ARROW OFFICEANDUnable to attend work

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Delivering Recruitment Solutions.Y ou must contact both at least 30 minutes before the start
of your shift.
When calling you must state the reason for your absence and
when you will be returning to work.
BLUE ARROW TEL No – 01332 282450
GROUP LEADER TEL No – IT IS YOUR RESPONSIBILITY
TO FIND OUT THEIR TEL No ON YOUR 1ST DAY.
If absence is over more than one shift you must repeat the
same procedure every day contacting both your Group
Leader and the Blue Arrow Office at least 30 minutes before
the start of your shift.
Failure to follow the absence procedure will be taken seriously.Unplanned non-attendance
Y ou will be issued with a Blue ‘Unplanned non-attendance’
card in your first day induction with Blue Arrow. On this card
will be the Blue Arrow office number, and space to record.
your group leader’s name and telephone number. As
mentioned earlier it is vital that you contact the office and
your group leader if you are unable to attend work, at least
30mins before the start of your shift.
Planned non-attendance
Y ou will also receive a Blue ‘Planned non-attendance’ card
on which you must put your name and return to your
group leader. This card monitors your holiday entitlements
throughout the year. Therefore, if you require a holiday, you
must consult your group leader so that they can refer to your
personal planned non-attendance form, and check that you
have enough entitlement remaining for what you want to
take. It is important that you give as much notice as possible
to ensure the date(s) you wish to take are available.
Equal Opportunities
Blue Arrow & T oyota Motor Manufacturing (UK) Ltd are both equal opportunities employers.