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In a series of
media releases leading up to the launch of the
new full hybrid Auris, Toyota is focusing on key
aspects of manufacturing operations, including
quality, training, logistics and TMUK’s leading
environmental management achievements. We begin
with an overview of how the company has
responded to the challenge of building Europe’s
first mass-produced hybrid vehicle.
The British car industry reaches a
landmark this month with the start of production of the Auris Hybrid by
Toyota Manufacturing UK (TMUK), the first mass-produced hybrid vehicle
to be built in Europe.
In investing in TMUK to build the new
full hybrid hatchback, Toyota has signalled its confidence in its UK
operations – the car plant at Burnaston in Derbyshire and the engine
factory at Deeside in North Wales – and in British manufacturing.
Established in 1992, TMUK was Toyota’s first European production base
and has benefited from £1.85 billion investment in its operations since
launch.
Following a challenging time for the
global motor industry, the opportunity for Toyota to take the lead with
the new full hybrid Auris model is a source of great pride for the TMUK
workforce, as Tony Walker, Deputy Managing Director, explained: “Auris
Hybrid provides a great opportunity for Toyota to increase sales and for
TMUK to increase production. Being the first to manufacture this new
technology is a source of immense motivation for everyone here at TMUK.”
Key challenges had to be met in
preparing for production of the new model and these have been achieved
in what was the shortest lead-time yet for any European-built model.
Although Auris Hybrid is a development of the conventional five-door
model already produced at Burnaston, its introduction has required
extensive training, new ways of working, new parts, alterations to the
production lines major changes to testing procedures. Not the least of
the challenges was the fact that although it is built on the same
production line as petrol and diesel Auris models, the hybrid takes 11
minutes longer to complete, calling for clever integration of new
equipment and specialist team members to ensure no bottlenecks occur.
Maintaining Toyota’s fundamental high
quality was essential and this has been supported by training for the
entire workforce in the special safety and technical requirements of
hybrid vehicle manufacturing. The training also includes a specially
developed Diploma in Hybrid vehicle Introduction and Environmental
Improvement that has been officially recognised as Level 2 NVQ.
Management and representatives of the
assembly and quality assurance teams have learned best practice from
their colleagues around the world, travelling to the Tsutsumi “mother”
factory in Japan, home of Prius, and to Toyota’s plant in Kentucky where
the hybrid Camry is built. In turn they have been able to provide
focused training for their colleagues in readiness for production
start-up.
The exceptional environmental
performance of the new Auris Hybrid, with CO2 emissions from 89g/km,
aligns perfectly with TMUK’s status as one of Toyota’s sustainable
factories, providing a lead in achieving the highest standards in
environmental management.
Burnaston was the first car plant in
the UK to achieve ISO 14001 certification and has reduced waste to
landfill and waste for incineration to zero. TMUK continues to cut
energy and water use and emissions from both its sites, with reductions
of more than 70 per cent achieved between 1992 and 2008. And, as well as
learning about and supporting best environmental practices in the
workplace, employees are also given support to reduce their carbon
footprint at home. TMUK also works with its local communities in
increasing environmental awareness.
The new Toyota Auris Hybrid will go on
sale in the UK and across Europe on 1 July.
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