The UK Factory Building Toyota's Most Important Hot Hatch: A Deep Dive into the GR Corolla's Production Process
The Toyota GR Corolla, a high-performance version of the iconic Corolla, is being produced in England, a surprising choice for a Japanese car manufacturer. This article delves into the reasons behind this decision and the intricate production process that ensures the GR Corolla's quality and precision.
The Choice of England
One might question why Toyota, with its extensive global factory network, chose England for the GR Corolla's production. The answer lies in the historical significance of the Motomachi plant in Japan, where Toyota's halo products are born. The Motomachi plant, known for its meticulous craftsmanship, is the pinnacle of Toyota's production network. However, it was reaching its production capacity limits, necessitating the search for a new location.
England, with its strong connection to motorsport and Toyota's desire to access this market, became the ideal choice. The UK plant, TMMUK, is now tasked with building the GR Corolla, a challenging endeavor that requires a dedicated production line and specialized personnel.
The GR Corolla Production Line
The GR Corolla's production process is a testament to Toyota's commitment to quality and precision. The line is modeled after the Motomachi plant, but with a unique twist. Instead of the usual 89-second production intervals, the GR line operates at 22-minute intervals, allowing for more intricate and technician-focused tasks.
This manual production process is a key differentiator. Each station on the GR line performs multiple tasks, requiring skilled workers who are often car enthusiasts. The workers are hand-chosen and trained for months on the regular Corolla line, ensuring they understand the importance of their role in building the GR Corolla.
Japanese Influence and Kaizen
The influence of Japanese working philosophies is evident throughout the factory. The workers, known as 'Members', are trained in Japanese methods and encouraged to contribute ideas for improvement. This 'Kaizen' philosophy, meaning continuous improvement, is a cornerstone of Toyota's production process.
The factory showcases numerous examples of Kaizen in action. From 3D-printed accessories to overhead conveyor belts, these innovations enhance safety and efficiency. The emphasis on Kaizen is reflected in the plant's culture, with regular competitions to identify the best improvements.
Quality Assurance and Testing
Quality assurance is a top priority at TMMUK. The production line's performance is judged by the target uptime of 98.6%, with screens displaying this number and errors. The 'Kaizen' method ensures continuous improvement, and the factory is filled with innovative solutions to enhance the production process.
The GR Corolla's quality is further assured through rigorous testing. Toyota organized track time with the UK-built cars at Brands Hatch circuit, where they performed identically to those built in Japan. This demonstrates the stringent production procedures and the ability to maintain consistency across different locations.
Conclusion
The production of the GR Corolla in England showcases Toyota's commitment to quality and precision. The UK plant, TMMUK, has embraced the Japanese philosophy of Kaizen and the Motomachi standard, resulting in a production process that rivals the best in the world. The GR Corolla's success in the North American market further emphasizes Toyota's strategic decision to build this important hot hatch in England.
As the GR Corolla continues to evolve, the UK plant's dedication to craftsmanship and innovation will undoubtedly contribute to its success, challenging the Motomachi plant to strive for even greater excellence.
