Let's delve into the fascinating world of automotive manufacturing and explore the story behind Toyota's decision to build its highly anticipated GR Corolla in the UK. It's a tale that goes beyond mere production logistics and reveals a deeper strategy rooted in Toyota's rich heritage and a unique appreciation for the UK's motorsport legacy.
The GR Corolla's Journey to the UK
Toyota's choice to manufacture the GR Corolla in England might seem peculiar at first glance, especially considering the company's vast global presence. However, this decision is far from arbitrary. It's a strategic move driven by the success of the GR Corolla and the need to expand production beyond Toyota's historic Motomachi plant in Japan, where the automaker's most prestigious models are born.
The Motomachi Legacy
Motomachi is a crown jewel in Toyota's production network. It's where iconic models like the Lexus LS400, LC500, and LFA, as well as the Toyota Supra and Century, have been crafted. The plant sets the standard for excellence, and Toyota aims to replicate this standard at its UK facility, Toyota Motor Manufacturing UK (TMMUK).
The Challenge of Building a GR Corolla
Building a GR Corolla is no ordinary task. It requires a dedicated production line and specialized personnel, as the process differs significantly from that of a regular Corolla. Toyota demands nothing less than Motomachi-level quality from TMMUK, and the plant's production leads are committed to achieving this goal.
Inside TMMUK
The main factory floor at TMMUK is a testament to efficiency and precision. Every 89 seconds, a new Corolla rolls off the line, with each station performing its task within this tight timeframe. The atmosphere is calm and focused, with workers moving fluidly and carefully. The entire production line is judged on its uptime and error rate, with a target of 98.6% uptime per shift.
The Philosophy of Kaizen
Toyota's commitment to continuous improvement, known as Kaizen, is evident throughout the factory. This Japanese philosophy is a core tenet of Toyota's production process, and it's celebrated and encouraged among the workers, who are referred to as "Members."
Japanese Influences at TMMUK
The influence of Japanese culture and working philosophies is apparent at TMMUK. From the worker safety briefings held in "Dojos" to the use of Japanese terms like "Hoshin" in planning documents, Toyota has integrated Japanese working methods into its UK plant. This cultural exchange is a unique aspect of the TMMUK story.
The GR Corolla Line
The GR Corolla line is a showcase of precision and craftsmanship. With a more compact layout and a technician-focused production process, each station handles multiple major assemblies. The process is highly manual, relying on the skill and passion of the workers, many of whom are car and motorsport enthusiasts. The line is explicitly modeled after Motomachi, with Toyota chiefs providing guidance and quality assurance.
The UK's Motorsport Legacy
Toyota's decision to build the GR Corolla in the UK is a nod to the country's rich motorsport history. As GR Corolla chief engineer Naohiko Saito puts it, "We chose the UK because it is the spiritual home of motorsport."
The Result
The UK-built GR Corollas prove to be of exceptional quality, performing identically to their Japanese counterparts on the track. This achievement is a testament to the stringent production procedures and the dedication of the TMMUK team. Akio Toyoda, the company's president, has personally visited the plant to emphasize the importance of precision and quality in GR car production.
A Challenge to Motomachi
The TMMUK team is ambitious, with some Members expressing their desire to one day surpass Motomachi's production standards. This competitive spirit is a driving force behind their commitment to excellence.
Conclusion
Toyota's decision to build the GR Corolla in the UK is a strategic move that combines the company's heritage with a respect for the UK's motorsport legacy. The TMMUK plant, with its commitment to Motomachi-level quality and its unique cultural influences, is a fascinating example of global automotive manufacturing. It's a story that showcases the passion and precision that go into crafting these iconic vehicles.
