The Toyota Indus Motor company, located at Port Bin Qasim Industrial Zone near Karachi, is the only manufacturing site in the world where both Toyota and Daihatsu brands are manufactured under the same roof. Along with state-of-the-art production technology, the facility has also implemented the world renowned Toyota Production System, that eliminates waste or ‘muda’ to enhance efficiency and productivity. Customer problem statement To create the body of the car, a spot-welding process is deployed. This requires high levels of current repetitively for several milliseconds during the operating cycle. The welders also operate in an asymmetrical manner across phases. All this leads to highly fluctuating reactive power and an unbalanced load current, causing large and uneve

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