Planning
Given that our vehicles are used in numerous countries, we examine what constitutes the ideal vehicle for each market and refine the concept to find the best fit.
Styling design
After the vehicle plan comes together, we begin shaping it from the ground up.
We create the shape of the ideal vehicle with our customers’ happiness in mind.
Design
Based on the finalized styling design, we optimize the overall vehicle to ensure comfort, ease of entry and exit, and efficient manufacturability.
We produce design data for all components, down to the most minute parts responsible for the vehicle’s safety and functionality.
This data is then used when we work with our partner companies to develop and manufacture each component and build prototype vehicles.
Testing and evaluation
We evaluate vehicle-related performance through a variety of rigorous tests.
Detailed tests of rough-road performance on various surfaces, safety performance, and opening/closing durability are conducted many times.
These tests replicate the roads, climates, and weather conditions found around the world. We use the test results to reassess and improve the prototype design, and then perform another round of testing.
We conduct repeated testing that doesn't rely only on data, but also takes human perception into account to build vehicles that surpass our customers’ expectations.
Product preparation
We promote Toyota Production System (TPS)-based production line improvements aimed at creating human-friendly processes, tools that put people front and center, and systems capable of responding quickly to change.
People-friendly manufacturing process
Our production engineering and plant divisions are fully engaged in assessing work postures that avoid heavy lifting and physical burden, and in establishing processes that are safe and enable workers to perform their tasks easily and reliably.
Designing people-centric tools
Fool-proof (FP) devices and parts-supply systems that match the order of assembly (sequential supply) are installed throughout the production line to safeguard safety and quality, even in the case of a human operational error. Our creative ideas proposal system allows workers to submit their ideas on enhancing ease of work and improving quality gained through their on-site insights to the company.
Production
We build the vehicle based on the finalized design and functionality.
The shape of a vehicle is only completed after the body is made and painted, and each part has been attached in the appropriate order. After assembly, a detailed quality inspection is carried out, and the finished vehicle is shipped.
Pressing process
Using some of the largest press machines in the industry, we manufacture the components that make up the vehicle, including the body, doors, and roof panels.
Welding process
Robots are used to heat and fuse the various parts produced in the pressing process together into the shape of the vehicle.
Painting process
We use environmentally friendly, water-based paint to coat the vehicle body. The paint is applied in four successive coats to give the vehicle its beautiful gloss.
We have introduced state-of-the-art, environmentally friendly equipment for that purpose.
Assembly process
This is where various parts are installed onto the painted vehicle body.
In the assembly process, the vehicle body is placed on a conveyor that moves at a constant speed, and many workers carefully and accurately attach the components.
Inspection process
To ensure customers can drive confidently and safely, the completed vehicles are carefully inspected in detail by both people and machines. Inspections are conducted to ensure compliance with applicable regulations.
Shipping
The vehicles that pass these strict inspections leave the plant and are delivered to dealerships and customers around the world.
