How your Toyota Land Cruiser is made? Toyota factory tour in Japan

Summary

The video highlights the Toyota auto body plant in Yoshiwara, Japan, where Land Cruiser models are produced. It details the highly automated pressing, welding, and painting processes used in manufacturing. The plant employs advanced techniques like spot, arc, and laser welding to ensure precision and durability. It also emphasizes Toyota's commitment to sustainability by reusing excess materials. The assembly process involves attaching major components like doors, windows, and the engine, followed by rigorous inspections. The facility produces over 10,000 vehicles daily, ensuring high-quality standards for global distribution.

Takeaways

• 🏭 The Toyota auto body plant in Yoshiwara, Japan, produces the Land Cruiser 300, Prado, and Land Cruiser 70.
• 🤖 Highly efficient pressing processes are implemented through automation, with adjustments for special small batches.
• ⚙️ Each pressing step takes only three seconds, applying 1,600 tons of pressure vertically.
• 🛡️ More than a dozen types of steel plates are used per car, with different materials optimized for safety and impact absorption.
• ♻️ Excess materials from steel plates are reused for other parts or recycled by steel companies.
• 🔩 Toyota uses mixed model production, allowing different types of vehicles to be manufactured on the same line.
• 🔥 Toyota employs three welding methods: spot welding, arc welding, and laser welding, with special robots welding over 500 locations for body strength.
• 🎨 The painting process starts with cleaning, followed by electro deposition coating and a middle coat that enhances the final color.
• 🧹 Strict rules and inspections are in place during the painting process to ensure high quality, including the use of static electricity to adhere paint.
• 🚗 The final assembly includes installing the engine, brakes, undercarriage, wiring, seats, and windows, with over 60,000 parts involved in vehicle production.

Q & A

What Toyota models are produced at the Yoshiwara plant in Japan?

The Toyota Land Cruiser 300, Land Cruiser Prado, and Land Cruiser 70 are produced at the Yoshiwara plant in Japan.

What makes the pressing process at the Yoshiwara plant efficient?

The pressing process is highly efficient due to automation, allowing for the production of special small batches and the ability to make several adjustments. Each step takes just three seconds and applies 1,600 tons of pressure.

Why are different steel plate types used in the car manufacturing process?

Different steel plate types are used based on the properties required for specific car parts. Hard materials are used in the cabin to protect occupants during a collision, while deformable materials are used in other areas to absorb impact.

How does Toyota's mixed model production work?

Mixed model production allows Toyota to manufacture various vehicle types on a single production line by rearranging the pressed parts in the order in which they are used.

What are the three major welding methods used by Toyota in the Yoshiwara plant?

The three major welding methods used are spot welding, arc welding, and laser welding. Spot welding uses electric current to fuse metal parts, arc welding uses an electric arc to join plates, and laser welding is for high-speed precision joining.

How are steel plates prepared before welding at the Yoshiwara plant?

Steel plates are cut and punched into part shapes with openings created where the doors will be attached. Excess materials from this process are reused in other parts or recycled by steel companies.

What is the purpose of the middle coat in the car painting process?

The middle coat, typically white, gray, or dark gray, helps enhance the appearance of the final body color, though it is not visible in the final product.

How does Toyota ensure high paint quality during the painting process?

Toyota ensures high paint quality by starting with a thorough cleaning process, using rust-resistant paint baths, applying a middle coat, and spraying a final clear coat for luster. They also bake the paint at 150°C for 20 minutes to improve durability.

What is the significance of displacing doors during the assembly process?

Doors are intentionally displaced during the assembly process because the weight of window glass and other components attached later will bring the doors back into alignment.

How many vehicles does Toyota produce daily in its Japan-based plants?

Toyota produces more than 10,000 vehicles per day in its Japan-based plants, which are then shipped to domestic dealerships and around the world.