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Each vehicle produced at Toyota Motor Manufacturing, Kentucky,
Inc., (TMMK) is made of thousands of quality parts. But like
a quilt, pieces are only the beginning.
The ideas, efforts and dedication of Kentucky team members
gives those pieces unity, strength and beauty as a finished
product.
Representatives from around the world come to Georgetown
to learn how the time-tested experience of Toyota combines
with Kentucky ingenuity at a state-of-the-art automaking facility.
Our production system has been honed since
the turn of the century into a model for the automobile
industry, and we're quite proud of how it helps us to make
some of the finest automobiles in the world.
You can learn more about the process, and our plant, by going
here. The sophisticated Toyota
Production System has a unique vocabulary that lets our
team members discuss specific elements precisely. Learn about
some of those terms here.
If you'd like a quick introduction to the process we use
to make our cars — just enough to make you sound smart
at parties — just scroll down.
You'll be an expert in no time.
STAMPING
At the beginning of each vehicle's 20-hour journey through
the production process, gleaming coils of steel — 95
percent of which is provided by domestic suppliers — are
cleaned, straightened and stamped into more than 200 body
components and parts. An in-house Die Manufacturing Shop
makes dies for Georgetown and other North American Toyota
Plants.
BODY WELD
A combination of human welders and more than 700 robotic
welders make more than 4,200 spot welds per vehicle, transforming
the steel parts into the strong body shell that is the foundation
for the finished vehicle.
PAINT
During more than ten hours in Paint, each vehicle shell undergoes
a complex series of prep, priming, sanding sealing and topcoating
processes designed to create a finish that is as durable and
corrosion-proof as it is beautiful.
PLASTICS
For efficiency and the ability to make improvements quickly,
instrument panels, glove-box covers and other plastic components
are produced on site.
POWERTRAIN
Kentucky-made engines have powered Camrys
since January 1990, and Avalons since
the model was launched. The Georgetown
Powertrain Plant produces four and six cylinder engines,
along with axle assemblies. In addition, engines and engine
components are manufactured for export.
ASSEMBLY
In assembly, each body shell is transformed into an operating
vehicle, as team members install everything from the engine
and electrical components to operating fluids and the insignia.
This is the largest area of production.
INSPECTION
At the end of assembly, each vehicle receives a quality inspection.
From the marshaling yard in Georgetown, vehicles are shipped
by rail and truck to distributors, dealers and customers across
America and around the world.
TEST TRACK
Every day, vehicles are chosen randomly to be put through
their paces on the two-mile test-track near the production
facilities. Team members from throughout the plant drive and
evaluate the vehicles as if they were new-car buyers.
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