Toyota explores innovative production methods to catch up with Tesla in EV market

Toyota production methods innovation: Toyota, the world's leading automaker, is implementing a series of innovative production methods at its factories in Japan's industrial hub to compete with Tesla and other electric vehicle (EV) manufacturers. Toyota aims to bridge the gap by combining new technologies with its renowned lean production techniques, known for their efficiency and cost-effectiveness.

Latest advancements

During a recent plant tour in central Japan, Toyota unveiled some of its latest advancements, including self-propelled assembly lines, substantial die-casting processes, and traditional hand polishing methods. Notably, the company demonstrated a cost-saving technique for creating high-gloss bumpers without using paint. The bumper mould is meticulously hand-polished to achieve a mirror-like finish, giving the bumper its shine.

Toyota has also automated three-decade-old equipment used for processing parts through robotics and 3D modelling, resulting in a threefold increase in equipment productivity. Toyota's Chief Product Officer, Kazuaki Shingo, emphasised the company's ability to adapt to changing times, rooted in its Toyota Production System (TPS).

Toyota revolutionised modern manufacturing with its lean production system, just-in-time delivery, and kanban workflow organisation. However, in the EV sector, Toyota has been outpaced by Tesla, a relentless innovator known for its market-leading profitability.

Under the leadership of CEO Koji Sato, Toyota unveiled an ambitious plan in June to accelerate its presence in the battery EV market. This marked a significant shift for the company, which had faced criticism for being slow to fully embrace electric technology. In 2022, Toyota held just about 0.3 per cent of the global EV market, according to Goldman Sachs.

Toyota is not the only automaker grappling with the challenges of transitioning to EVs. Detroit's Big Three automakers have cited competitive pressure from Tesla while facing labour disputes with the United Auto Workers union.

Innovations 

Toyota's innovations include self-propelled production lines, where EVs are guided by sensors through the assembly process, eliminating the need for costly conveyor equipment and providing greater production line flexibility. Toyota also showcased "gigacasting" technology, pioneered by Tesla, which produces large aluminium parts for modular EV construction.

In addition, Toyota introduced a self-driving transport robot at its Motomachi plant in Toyota City, which transports new vehicles across a large parking lot, a task traditionally performed by human drivers. The automaker plans to deploy ten of these robots at the Motomachi plant by next year and is exploring options to sell them to other companies.

Toyota's innovative approaches underscore its commitment to remain competitive in the rapidly evolving EV market and regain its leadership position.

(With Reuters Inputs)