Toyota's decision to build its GR Corolla in England is a strategic move that goes beyond simple manufacturing. It's a testament to the company's commitment to quality, innovation, and the spiritual home of motorsport. This article delves into the intricate process, the cultural influences, and the passion that drives this production line, offering a unique perspective on a seemingly straightforward decision.
A Strategic Choice
At first glance, the choice of England for the GR Corolla's production might seem odd. After all, Toyota has more factories than most people will have shoes in their lifetime. However, this decision is far from arbitrary. The GR Corolla, a victim of its own success, required a production line that could match the standards of Toyota's historic Motomachi plant in Japan. This plant, known for building Toyota's halo products, is the crown jewel of the company's production network.
The GR Corolla's production process is a marvel in itself. It's an entirely separate process from the regular Corolla, with specialized personnel, different tooling, and unique methods. Building the GR Corolla to the Motomachi standard required a new production line and a dedicated staff, and Toyota settled for nothing less than the best.
The Production Line
The GR Corolla line is a testament to the precision and efficiency of Toyota's production process. Each station in the line has a specific task, with the entire process taking about 22 minutes per car. This is a far cry from the regular Corolla line, which takes 89 seconds per car. The GR line is more compact, with fewer specialized machines, but each station does more tasks, requiring a more technician-focused approach.
The workers on the GR line are hand-chosen and trained for months on the regular line. They are car and motorsport enthusiasts who understand the importance of their role. The passion and pride they bring to the job are palpable, and the sense of being 'trusted' to build the GR Corolla is evident in every aspect of the production process.
The Cultural Influence
The production line is heavily influenced by Japanese working philosophies and methods. The worker safety briefing areas are called Dojos, and the plant is filled with Japanese terms like 'Hoshin' (direction) and 'Kaizen' (continuous improvement). The workers are encouraged to speak up about improvements and weaknesses, and regular competitions are held to find the best Kaizen.
The plant is filled with innovative solutions, such as reshaped 3D-printed accessories that prevent tools from falling and an overhead conveyor belt that safely transports wiring harnesses. These solutions are a testament to the plant's commitment to safety, efficiency, and quality.
The Result
The GR Corolla built in England is a marvel of precision and care. The cars are measured against the standards of Motomachi, and according to GR Corolla chief engineer Naohiko Saito, they are as good or better. The experience of testing the cars at Brands Hatch circuit proved just how stringent modern production procedures are, and how two cars can be made identically, regardless of location.
The Future
The UK plant is primarily providing extra units for the demanding North American market, while Motomachi continues to stamp out GR Corollas as quickly as it can. The target is Motomachi, and the workers at the UK plant are determined to beat the Japanese standards one day. This is a testament to the passion and commitment of Toyota's workforce, and a reminder that the company's success is built on more than just manufacturing.
In conclusion, Toyota's decision to build the GR Corolla in England is a strategic move that goes beyond simple manufacturing. It's a testament to the company's commitment to quality, innovation, and the spiritual home of motorsport. The production line is a marvel of precision and care, and the cultural influences are evident in every aspect of the process. The result is a car that is as good or better than the one built in Japan, and a workforce that is passionate and committed to the task at hand.
