The UK Factory Building Toyota's Most Important Hot Hatch: A Deep Dive into the GR Corolla's Production Process
Toyota's decision to build its GR Corolla in England is a strategic move that goes beyond mere manufacturing. It's a testament to the company's commitment to quality, innovation, and a deep-rooted connection to the UK's rich motorsport heritage. This article delves into the intricate process behind the GR Corolla's production, exploring the unique challenges and meticulous attention to detail that sets it apart from conventional Toyota models.
A Crown Jewel in Toyota's Production Network
The GR Corolla is a halo product, and its production is entrusted to the prestigious Motomachi plant in Japan. This plant, known for its meticulous craftsmanship, is the birthplace of Toyota's most prestigious vehicles, including the Lexus LS400, LC500, LFA, Toyota Supra, and the iconic Century. Building the GR Corolla requires an entirely new production line and a dedicated staff, adhering to the Motomachi standard. This level of commitment ensures that the GR Corolla embodies the pinnacle of Toyota's engineering and quality.
The Target is Motomachi
The phrase "The target is Motomachi" resonates throughout the Toyota Motor Manufacturing UK (TMMUK) facility. This mantra reflects the company's relentless pursuit of excellence and the desire to emulate the Motomachi plant's precision and efficiency. The production line's performance is judged on achieving this target, with a focus on minimizing stoppages and errors. The line uptime target is an impressive 98.6%, ensuring that the production process is moving for 98.6% of each shift.
Kaizen: The Philosophy of Continuous Improvement
At the heart of TMMUK's success is the Japanese philosophy of Kaizen, which translates to "continuous improvement". This philosophy is evident in every aspect of the factory, from the worker safety briefing areas called Dojos to the planning documents using the Japanese word for direction, Hoshin. Workers, known as Members, are trained in Japanese working methods and encouraged to contribute ideas for improvements and address weaknesses. Regular competitions among teams foster innovation, with Kaizens celebrated and highlighted throughout the plant.
One notable example of a Kaizen is the 3D-printed accessories that prevent heavy tools from falling from their holster, ensuring worker safety. Another is the overhead conveyor belt that safely transports wiring harnesses, reducing the risk of damage from workers accidentally stepping on connectors.
The GR Corolla Line: A Manual Assembly Process
The GR Corolla production line stands in stark contrast to the regular Corolla line. While the latter sprawls across a vast facility, the GR line is more compact, taking up only a third of the space. The GR line's production process is shockingly manual, with each station performing multiple tasks, taking about 22 minutes instead of the 89 seconds of the regular Corolla line. This manual approach relies heavily on the skill and expertise of the workers, who are hand-chosen for their passion and knowledge of cars and motorsport.
A Japan-Made GR Corolla
The GR Corolla's production is a testament to Toyota's commitment to quality and craftsmanship. Almost every part of the GR Corolla is still Japan-made, with engines, subframes, brakes, suspension, and major running gear imported. The bodies and body panels are stamped out at TMMUK, subjected to extra stringent checks, and then scanned for accuracy down to a hundredth of a millimeter. The final product is measured against the standards set by Motomachi, and according to GR Corolla chief engineer Naohiko Saito, it meets or exceeds those standards.
The Result: A High-Performance GR Corolla
Toyota's confidence in the UK-built GR Corolla is evident in the company's decision to test the cars at Brands Hatch circuit. The experience proved the stringent production procedures and the high quality of the UK-built cars. Despite the manual assembly process, the GR Corolla's performance on the track was identical to that of the Motomachi-built models. The UK's brisker weather even contributed to better cooling, showcasing the car's ability to handle abuse and maintain consistent performance.
Conclusion: A Strategic Move with a Rich Heritage
Toyota's choice of the UK for the GR Corolla's production is a strategic move that leverages the country's rich motorsport heritage. As GR Corolla chief engineer Naohiko Saito stated, "We chose the UK because it is the spiritual home of motorsport. Morizo knows the importance of the UK and wanted to access it to improve the GR Corolla even more."
In conclusion, the GR Corolla's production process in the UK is a testament to Toyota's commitment to quality, innovation, and a deep connection to the UK's motorsport legacy. The meticulous attention to detail, the manual assembly process, and the reliance on skilled workers all contribute to the creation of a high-performance, meticulously crafted vehicle that embodies the pinnacle of Toyota's engineering prowess.
